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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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Design and validation of fault-tolerant flight systems

Flight systems must be validated to show that they are consistent with the requirements of their intended applications. While high reliability is difficult to validate, the additional complexity of fault tolerance further compounds the validation problem. The objective of NASA’s research is to develop a methodology for designing validatable fault-tolerant systems. Under the design-for-validation philosophy, emphasis is placed on developing validation methods that can be incorporated into the design process right from the start and design methods and guidance which, while incorporating fault tolerance, can assure validatability. This paper examines the statistical issues of validating highly reliable, fault tolerant system. There are many problems associated with traditional methods of designing and validating these potentially complex hardware and software systems. Useful design-for-validation methods, which include structured specification and design methodologies, mathematical proof techniques, analytical modeling, simulation and emulation, and physical testing, are discussed. Important design issues associated with fault tolerance are presented along with the related validation concerns which must be addressed. Experience has shown that synchronization and Byzantine resilience must accompany fault tolerance. Other design attributes associated with fault tolerance may be used by a designer on the basis of cost, weight, performance, and validation considerations.

Computer systems↗

National Aerospace Plane Engine Seals: High Temperature Seal Performance Evaluation

The key to the successful development of the single stage to orbit National Aerospace Plane (NASP) is the successful development of combined cycle ramjet/scramjet engines that can propel the vehicle to 17,000 mph to reach low Earth orbit. To achieve engine performance over this speed range, movable engine panels are used to tailor engine flow that require low leakage, high temperature seals around their perimeter. NASA-Lewis is developing a family of new high temperature seals to form effective barriers against leakage of extremely hot (greater than 2000 F), high pressure (up to 100 psi) flow path gases containing hydrogen and oxygen. Preventing backside leakage of these explosive gas mixtures is paramount in preventing the potential loss of the engine or the entire vehicle. Seal technology development accomplishments are described in the three main areas of concept development, test, and evaluation and analytical development.

Steinetz, Bruce M.↗

Temperature Distributions in Semitransparent Coatings: A Special Two-Flux Solution

Radiative transfer is analyzed in a semitransparent coating on an opaque substrate and in a semitransparent layer for evaluating thermal protection behavior and ceramic component performance in high temperature applications. Some ceramics are partially transparent for radiative transfer, and at high temperatures internal emission and reflections affect their thermal performance. The behavior is examined for a ceramic component for which interior cooling is not provided. Two conditions are considered: (1) the layer is heated by penetration of radiation from hot surroundings while its external surface is simultaneously film cooled by convection, and (2) the surface is heated by convection while the semitransparent material cools from within by radiant emission leaving through the surface. By using the two-flux method, which has been found to yield good accuracy in previous studies, a special solution is obtained for these conditions. The analytical result includes isotropic scattering and requires only an integration to obtain the temperature distribution within the semitransparent material. Illustrative results are given to demonstrate the nature of the thermal behavior.

Siegel, Robert↗

High-throughput and high-performance lithium-ion batteries via dry processing

A scalable powder-to-electrode dry processing strategy mainly based on powder dry mixing and rolling/calendering is rationally designed. The dry processed electrodes show lower tortuosity compared to that of conventional slurry-based electrodes. The dry-processed high-loading graphite anodes (6.6 mAh cm -2 ) and LiNi 0.6 Mn 0.2 Co 0.2 O 2 cathodes (6.0 mAh cm -2 ) exhibit promising electrochemical performance in half-cells and full-cells. The full-cells with both electrodes from dry processing demonstrates superb rate performance to their counterpart with conventional slurry-based electrodes and delivers of capacity retentions of 74.1 % and 63.6 % over 400 and 800 cycles, respectively. Notably, the initial Coulombic efficiency of the dry processed graphite anodes is low ascribed to polytetrafluoroethylene binder. Finally, the results suggest that dry processing is promising for future lithium-ion battery manufacturing and also pinpoint the needs of modification for the polytetrafluoroethylene binder in the graphite anodes.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Analysis of Ionic Mercury Species in SRR Samples Measured by SRNL and Eurofins FGS

Savannah River Remediation (SRR) requested the development of mercury speciation capabilities at the Savannah River National Laboratory (SRNL) to support the Liquid Waste Operations at SRS. As part of that method development, SRR requested that SRNL Analytical Development (AD) compare their results with those obtained from their outside contract laboratory, Eurofins Frontier Global Sciences (FGS). This document reports on this method development work performed at SRNL as well as the comparative analyses conducted between the two laboratories. Development, optimization, and validation were undertaken at SRNL to produce a method for the species-specific analysis of ionic mercury. This method was developed as a secondary step to an existing method, L16.1-ADS-1579 Purgeable Mercury Cold Vapor Atomic Fluorescence Spectrophotometry. As such, much of the development and validation were performed in service of development of L16.1-ADS-1579. Six samples, representing two consecutive quarterly Tank 50 batches, were tested for ionic mercury by SRNL-AD and Eurofins FGS. The mean values reported by each lab for ionic mercury differed by less than one standard deviation, therefore the values reported by both labs were considered to be in agreement. SRNL-AD reported values for the six samples that differed by -5.56 mean percent, relative to Eurofins FGS. Together with comparable quality control data reported by each laboratory, these data represent a high level of agreement among both laboratories. With a viable method for ionic mercury that matches the data quality provided by outside commercial laboratories, SRNL-AD has demonstrated competency in measuring methylmercury, ethylmercury, total mercury, soluble & particulate mercury, purgeable mercury, and ionic mercury species in a variety of radioactive tank samples.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Fully Conjugated Poly(phthalocyanine) Scaffolds Derived from a Mechanochemical Approach Towards Enhanced Energy Storage

Phthalocyanines (Pc)-derived materials represent an attractive category of porous organic scaffolds featured by extensive π-conjugated networks, but their construction is still limited to the solution-based pathways, producing materials with inferior conductivity and porosity. Herein, a mechanochemistry-driven approach was developed leveraging the on-surface polymerization of aromatic nitrile monomers with ortho-positioned dicyano groups in the presence of metal catalysts (magnesium, zinc, or aluminum) under neat and ambient conditions. Diverse Pc-functionalized conjugated porous networks (Pc-CPNs) were obtained featured by extensively and fully π-conjugated skeletons, high surface areas, and hierarchical porosities. The monomers in this mechanochemical approach could be extended to those difficult to be handled in solution-based procedures. In this work, the Pc-CPNs displayed attractive electrochemical performance as supercapacitor and anodes in batteries, together with superb long-term stability.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

The role of quantum computing in advancing scientific high-performance computing: A perspective from the ADAC institute

Quantum computing (QC) has gained significant attention over the past two decades due to its potential for speeding up classically demanding tasks. This transition from an academic focus to a thriving commercial sector is reflected in substantial global investments. While advancements in qubit counts and functionalities continue at a rapid pace, current quantum systems still lack the scalability for practical applications, facing challenges such as too high error rates and limited coherence times. Here, this perspective paper examines the relationship between QC and high-performance computing (HPC), highlighting their complementary roles in enhancing computational efficiency. It is widely acknowledged that even fully error-corrected QC will not be suited for all computational tasks. Rather, future compute infrastructures are anticipated to employ quantum acceleration within hybrid systems that integrate HPC and QC. While QC can enhance classical computing, traditional HPC remains essential for maximizing quantum acceleration. This integration is a priority for supercomputing centers and companies, sparking innovation to address the challenges of merging these technologies. The novelty of this work lies in its unique perspective, reflecting the collective insights of the Accelerated Data Analytics and Computing (ADAC) Institute, a global consortium of over 20 leading HPC centers. Recognizing the growing importance of QC, ADAC established a Quantum Computing Working Group in 2023 to foster collaboration and knowledge-sharing among its members. This paper synthesizes insights from the group’s collaborative efforts and incorporates findings from a member survey that captures shared experiences, ongoing projects, and strategic directions. By outlining the current landscape and challenges of QC integration into HPC ecosystems, this work offers HPC specialists practical and forward-looking guidance on the opportunities and implications of QC in computationally intensive endeavors.

Accelerated Data Analytics and↗

Quasi-Two-Dimensional Earth-Abundant Bimetallic Electrocatalysts for Oxygen Evolution Reactions

The extremely large surface area offered by quasi-two-dimensional (2D) nanostructures is a great advantage for catalytic applications. While bimetallic materials have been discovered as a group of promising catalysts for electrochemical water splitting, a facile and reliable synthesis approach toward 2D morphology to fully release its electrochemical catalytic potential is still lacking. In this work, bimetallic Co–Mo–O ultrathin nanosheets were synthesized by ionic layer epitaxy with controlled composition ratio. The Co–Mo–O nanosheets exhibited a quadrangle shape with a uniform thickness of ~2.5 nm. This 2D morphology largely enriched the surface catalytic active site ratio. Particularly, nanosheets with 2:1 Co-to-Mo ratio showed a substantially enhanced OER catalytic activity with a 3 orders of magnitude higher mass activity compared to benchmark IrO 2 and RuO 2 in an alkaline environment. Furthermore, this study introduces a promising possibility for creating high-performance electrocatalysts from 2D bimetallic materials with a high efficiency for material utilization.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Renewable linear alpha-olefins by base-catalyzed dehydration of biologically-derived fatty alcohols

In this work, base catalysts were studied for the dehydration of fatty alcohols to linear alpha olefins (LAOs). For the dehydration of 1-octanol to 1-octene, 15%Cs/SiO 2 catalyst was 56% selective at 10% conversion. Diluting a feed of C 8 , C 10 , and C 14 fatty alcohols to 50% in undecane increased the selectivity to alpha olefins to 77-99%. 15%Cs/SiO 2 was further investigated for the dehydration of a 4.2 g/L mixed C 8 -C 14 fatty alcohol in tridecane feed and showed linear alpha olefin selectivities of 78-100% at initial conversions of 51-91% with the conversion lowering to 32-77% over 30 h. Catalytic activity was totally regenerated through calcination. A feed of biologically derived alcohols was produced with E. coli strain CM24 transformed with three plasmids (pBTRCk – pVHb – maACR, pACYC – pVHb – seFadBA, pTRC99A – pVHb – tdTER – fdh) which yielded a 5.5 g/L of C 8 -C 14 fatty alcohol in tridecane. This biologically-derived feed was successfully dehydrated to linear alpha olefins over 15%Cs/SiO 2 at selectivities of 60-100% with initial conversions of 35-75% which decreased to 22-55% over 30 h. Techno-economic analysis (TEA) of the integrated process for fatty alcohol production and subsequent dehydration to alpha olefins was conducted across the potential fermentation TRY (titer, rate, yield) landscape. Baseline fermentation performance resulted in a minimum product selling price (MPSP) double the market price for LAOs due to low titers and high costs associated with managing water and tridecane solvent flows through the system. However, targeted improvements in fermentation performance (e.g., achieving 40 g/L titer, 0.5 g/L/h productivity, 80% theoretical yield) can enable financially viable production of biologically derived LAOs.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

FY2021 Improvements to the New CTH Code Verification & Validation Test Suite

Over the past few years, the CTH multiphysics hydrocode has overhauled its software quality and testing processes, implementing current best practices in software quality and building a robust V&V test suite comprised of traditional hydrocode verification problems, including ASC Tri-Lab Test Suite and Enhanced Tri-Lab Test Suite problems, as well as validation problems for some of CTH’s most frequently used equations of state, materials models, and other key capabilities. Substantial progress towards building this new test suite was made in FY19 and FY20. In FY21, the test suite has been expanded to include verification and validation tests of the Steinberg-Guinan-Lund (ST) viscoplastic model and the Johnson Cook (JFRAC) fracture model. Additionally, two new verification tests were added, covering hydrodynamics and high explosive (HE) modeling capabilities: the Kidder Gaussian density problem and the Escape of HE Products (EHEP) problem from the Tri-Lab Test Suite. This report discusses each of these test problems in detail. Verification test results are compared to analytic solutions. Validation test results are compared to experimental data. Wherever possible, convergence or mesh refinement studies are included. Additionally, while implementing the Kidder verification problem, a bug was identified that affects the use of tables to initialize pressure or density in 1D or 2D calculations. A brief discussion of the bug and its fix is included. CTH demonstrates good performance overall on the new test suite problems. Simulation results showed good agreement with analytic solutions for the Kidder problem, with convergence rates ranging between 1.8 and sub-linear, and relatively good agreement for the EHEP problem, though convergence rates for pressure and density were nearly 0. The ST and JFRAC strain rate loading verification tests show good agreement with analytic solutions. Likewise, CTH simulation results show good agreement with experimental validation data, including Taylor rod impact testing, for the materials tested. Future V&V work will focus on adding 2D and 3D versions of existing verification tests as well as adding validation tests of other frequently used capabilities such as other fracture models.

42 ENGINEERING↗

Evaluation of Minimum Detectable Activities for Stack Sample Analyses

The Rad-NESHAP program takes samples at major point sources to track how much of select nuclides are being emitted out of the stack. Samples are taken at the site where the radiological operations are being performed. The samples are then sent to analytical laboratories for analysis to determine what nuclides exist in the sample. However, due to the sensitivity of the instruments, false positives are often reported. To reduce the number of false positives, the results reported from the analytical labs are compared to set detection limits. Anything below the set detection limit is considered part of the background while anything above the limit is considered a positive hit. Therefore, the detection limit must be set low enough that any false negatives do not result in a significant dose missed at the end of the year but high enough that there are not enough false positives to skew the annual dose being reported. All detection limits listed in this section for the analyses below were designed to meet the stated equivalent emissions rate and subsequent off-site doses. These minimum detectable activities (MDAs) were developed in the 1990s and documented in the memo cited for each analysis below. These limits and memos are all currently referenced in the Quality Assurance Project Plan (QAPP) for the Rad-NESHAP Compliance Task, which is being updated to a Project Implementation Plan (PIP) concurrently with this document. As part of this update process, the original MDAs defined in this section needed to be verified that they were still conservative and meet the off-site dose levels stated.

2019 MDA↗

SAM Code Enhancements for Fission Product Tracking of Noble Gases and Metals in MSRs

This report documents fiscal year 2026 enhancements to the System Analysis Module (SAM) for modeling fission product transport in liquid-fueled molten salt reactors (MSRs). The work advances three principal areas: noble gas transport, noble metal deposition, and user interface improvements. The noble gas transport capability integrates drift-flux gas transport, Henry’s law two-film interphase mass transfer with pressure-based nucleation suppression, Knudsen-regime pore diffusion into porous graphite with a conjugate salt-graphite interface constraint, built-in material properties, five Sherwood-number mass transfer correlations including three derived from high-fidelity NekRS simulations, and xenon-135 reactivity feedback through SAM’s point-kinetics model. This work also presents a comprehensive verification test suite, including new analytically verified cases for pressure-dependent onset of interphase gas transfer in a stagnant vertical pipe, a postulated FLiBe-graphite Xe extraction permeator, a gravity riser with a fission-product source, and a descending pipe with gas redissolution driven by hydrostatic pressure. A machine learning framework for bubble rise velocity prediction in molten salt systems is developed and benchmarked on molten-salt and diverse aqueous bubble datasets. The best-performing fine-tuned transfer-learning networks achieve an 82% reduction in RMSE relative to the Clift correlation, and is implemented directly in SAM. The noble metal transport capability is developed, including a liquid-wall deposition model and a gas-surface flotation mechanism that transfers insoluble particles entrained by sparging gas to wetted structures. Verification tests and demonstration cases cover the surface deposition, flotation efflux, and flotation shedding. Finally, a new [SpeciesTransport] input structure replaces positional global vectors with selfcontained, order-independent, named species blocks, simplifies the specification of multiphase species and decay chains, and remains fully compatible with existing SAM input files. Together, these developments improve the physical fidelity, verification basis, and usability of SAM for system-level analyses of fissionproduct behavior in MSRs.

Mui, Travis (ORCID:0000000303736470)↗

Development of CFD code evaluation criteria and a procedure for assessing predictive capability and performance

Careful validation of computational fluid dynamic (CFD) codes is essential if they are to be used as engineering design tools. Validation must be carried out in a systematic manner to ensure that all code aspects as they apply to the application of interest are understood and, to the greatest extent possible, quantified. A study is being conducted in which a general code validation procedure is defined and demonstrated. A four phase validation procedure is defined in which a series of validation test cases are computed and compared with available analytical solutions and test data. The procedure is demonstrated using the REACT CFD code to compute validation cases for each of the four phases. For phase four, the application of interest, the Space Shuttle Main Engine high pressure fuel turbopump impeller flow field, is computed.

Lin, S. J.↗

Low and high velocity impact response of thick hybrid composites

The effects of low and high velocity impact on thick hybrid composites (THC's) were experimentally compared. Test Beams consisted of CFRP skins which were bonded onto an interleaved syntactic foam core and cured at 177 C (350 F). The impactor tip for both cases was a 16 mm (0.625 inch) steel hemisphere. In spite of the order of magnitude difference in velocity ranges and impactor weights, similar relationships between impact energy, damage size, and residual strength were found. The dependence of the skin compressive strength on damage size agree well with analytical open hole models for composite laminates and may enable the prediction of ultimate performance for the damaged composite, based on visual inspection.

Hiel, Clement↗

Orbital Transfer Vehicle Engine Technology High Velocity Ratio Diffusing Crossover

High speed, high efficiency head rise multistage pumps require continuous passage diffusing crossovers to effectively convey the pumped fluid from the exit of one impeller to the inlet of the next impeller. On Rocketdyne's Orbital Transfer Vehicle (OTV), the MK49-F, a three stage high pressure liquid hydrogen turbopump, utilizes a 6.23 velocity ratio diffusing crossover. This velocity ratio approaches the diffusion limits for stable and efficient flow over the operating conditions required by the OTV system. The design of the high velocity ratio diffusing crossover was based on advanced analytical techniques anchored by previous tests of stationary two-dimensional diffusers with steady flow. To secure the design and the analytical techniques, tests were required with the unsteady whirling characteristics produced by an impeller. A tester was designed and fabricated using a 2.85 times scale model of the MK49-F turbopumps first stage, including the inducer, impeller, and the diffusing crossover. Water and air tests were completed to evaluate the large scale turbulence, non-uniform velocity, and non-steady velocity on the pump and crossover head and efficiency. Suction performance tests from 80 percent to 124 percent of design flow were completed in water to assess these pump characteristics. Pump and diffuser performance from the water and air tests were compared with the actual MK49-F test data in liquid hydrogen.

Lariviere, Brian W.↗

Spacecraft Priming Analysis and Research Test Apparatus: Number 1 (SPARTAN 1), Test and Analysis Results

Spacecraft with Earth-storable propellants are required by range safety to launch with propellant isolated from the thrusters for ground operations, which is often accomplished by placing a pyrotechnic, or a latching isolation valve between the tank and the thrusters. Once on-orbit, downstream lines are vented out to space through the thrusters and are left evacuated and at vacuum pressure. Propellant isolation valve then opens and floods the lines with high velocity propellant which can lead to a significant pressure surge upon filling. Replicating this event during ground testing using water as a propellant simulant has always been difficult and costly to accurately perform due to the low vacuum pressure targeted on the downstream side of the system. This report describes the Spacecraft Priming Analysis and Research Test Apparatus (SPARTA) at Marshall Space Flight Center’s (MSFC) Component Development Area (CDA) and the initial test series meant to be a pathfinder for construction methods and test procedures to reduce the cost of future testing. The test data collected are critical to analytical models as the details to replicate prior ground tests are often lacking in enough detail to adequately model the test that was conducted. This report also describes the Thermal Desktop/FloCAD analysis that was performed alongside the test series. The test methods defined for this campaign showed a dramatic improvement on heritage test procedures. Test pace increased due to faster drying and pulling vacuum more effectively. Results generated in this test matched analytical predictions very well and provide a releasable set of test data to be leveraged on future NASA and commercial partner spacecraft development programs.

spacecraft↗

Facile Synthesis of Micrometer-sized Hierarchical Porous Si@C Anodes for High-Performance Lithium-Ion Batteries

Extensive studies have been conducted to determine if replacing graphite anodes with silicon is feasible since silicon possesses a high capacity and is an abundant resource; however, Si anodes suffer significant volume changes during cycling, which pulverizes its structure and subsequently causes rapid capacity fading. We used SiO2 nanoparticles (nSiO2) and low-cost coal-derived humic acid as a feedstock to synthesize high performance Si-C anodes for Li-ion Batteries through spray drying, calcination, and magnesiothermic reductions. Our Si-C anodes features micrometer-sized porous Si coated with a graphitized carbon shell (mpSi@C). The hierarchical graphitized carbon shell and porous silicon structure relieve the mechanical stress of the Si phase upon cycling, which stabilizes the structure. This mpSi@C composite design allows for a high initial discharge capacity of 2199.9 mAh g-1 at 0.1 A g-1 and a cycling performance of 68% capacity retention after 100 cycles at 1.0 A g-1. The multipoint contact between the Si anode and C structure allows for a remarkable performance rate of 566.3 mAh g-1 at 5.0 A g-1.

01 COAL, LIGNITE, AND PEAT↗

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