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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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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Battery Relevant Cell Side Wall Rupture Characterization

The propensity for a cell design to experience can side wall rupture (SWR) during thermal runaway is highly influenced by how a battery design mechanically constrains its cells. Testing cells while unsupported has been found to yield false negative results that don't represent this risk in a battery configuration. This talk addresses how to verify the adequacy of battery design measures used to control SWR and how to get results relevant, accurate, and statistically defendable for a proposed battery design.

thermal runaway↗
NASA NTRS2026

The Operational NASA Anomaly Gas Analyzer and Exploration Follow-Ons

The NASA Anomaly Gas Analyzer (AGA) is the culmination of nearly ten years of advancement of core technology originally developed by Vista Photonics through the Small Business Innovation Research (SBIR) program and expanded using NASA program funding. The AGA is a portable, battery operated, optical gas detection instrument for continuous monitoring of H 2 O, CO 2 , O 2 , CO, NH 3 , HCN, HF, HCl in the spacecraft environment. Real time, in-situ monitored, gas concentrations are communicated at 1 Hz through a built-in display on-orbit and additionally through a serial interface on the ground. The instruments function over the typical range of temperatures and pressures required for the spacecraft environment. A ten-year operational life is targeted. Seven AGA instruments are currently deployed on the International Space Station and two Orion-specific units are manifested for Artemis 2. A variation of the operational AGA is under development for lunar Human Landing Systems. A wider calibrated operating pressure envelope is required in this application. Otherwise, the instruments straightforwardly address lessons learned from the original AGA by improving aspects of thermal control, ruggedness, and ease-of-use. A subset of AGA-developed sensed gases (H 2 O, CO 2 , O 2 ) is the subject of the Primary Constituent Monitor (PCM) development for the Habitation and Logistics Outpost (HALO) destined for lunar orbit. Two PCMs will be installed in HALO as part of the environmental control loop where they will interface with vehicle power and communications. While the basic sensor techniques are unchanged from the AGA, these instruments have been radiation hardened to survive for many years in the harsh target environment. Current development status for these instruments will be presented along with recent developments of a naval submarine variant.

Air Monitoring↗
NASA NTRS2024

Ejecta Management in a Safe Lithium Ion Battery Design

As lithium-ion battery energy densities continue to rise, managing the heat and pressure generated during failure events has become increasingly critical. Safety systems must effectively relieve pressure without releasing sparks, flames, or particulate matter, requiring robust filtration solutions. The challenge is compounded by the reduced free volume available for gas expansion in high-density designs, which increases the demands on these filters. While significant progress has been made through experimental studies and modeling efforts to understand the behavior of ejecta during battery failures, there remains a pressing need for practical, rule-of-thumb sizing parameters. These parameters would help correlate high-energy waste streams with appropriate filter design, ensuring reliable containment and safety. This talk will explore recent experimental findings in this area and discuss the potential pathways for developing these essential sizing guidelines.

Ejecta Management↗
NASA NTRS1996

Planetary and Deep Space Requirements for Photovoltaic Solar Arrays

In the past 25 years, the majority of interplanetary spacecraft have been powered by nuclear sources. However, as the emphasis on smaller, low cost missions gains momentum, more deep space missions now being planned have baselined photovoltaic solar arrays due to the low power requirements (usually significantly less than 100 W) needed for engineering and science payloads. This will present challenges to the solar array builders, inasmuch as planetary requirements usually differ from earth orbital requirements. In addition, these requirements often differ greatly, depending on the specific mission; for example, inner planets vs. outer planets, orbiters vs. flybys, spacecraft vs. landers, and so on. Also, the likelihood of electric propulsion missions will influence the requirements placed on solar array developers. This paper will discuss representative requirements for a range of planetary and deep space science missions now in the planning stages. We have divided the requirements into three categories: Inner planets and the sun; outer planets (greater than 3 AU); and Mars, cometary, and asteroid landers and probes. Requirements for Mercury and Ganymede landers will be covered in the Inner and Outer Planets sections with their respective orbiters. We will also discuss special requirements associated with solar electric propulsion (SEP). New technology developments will be needed to meet the demanding environments presented by these future applications as many of the technologies envisioned have not yet been demonstrated. In addition, new technologies that will be needed reside not only in the photovoltaic solar array, but also in other spacecraft systems that are key to operating the spacecraft reliably with the photovoltaics.

C P Bankston↗
NASA NTRS2014

Crewed Space Vehicle Battery Safety Requirements

This requirements document is applicable to all batteries on crewed spacecraft, including vehicle, payload, and crew equipment batteries. It defines the specific provisions required to design a battery that is safe for ground personnel and crew members to handle and/or operate during all applicable phases of crewed missions, safe for use in the enclosed environment of a crewed space vehicle, and safe for use in launch vehicles, as well as in unpressurized spaces adjacent to the habitable portion of a space vehicle. The required provisions encompass hazard controls, design evaluation, and verification. The extent of the hazard controls and verification required depends on the applicability and credibility of the hazard to the specific battery design and applicable missions under review. Evaluation of the design and verification program results shall be completed prior to certification for flight and ground operations. This requirements document is geared toward the designers of battery systems to be used in crewed vehicles, crew equipment, crew suits, or batteries to be used in crewed vehicle systems and payloads (or experiments). This requirements document also applies to ground handling and testing of flight batteries. Specific design and verification requirements for a battery are dependent upon the battery chemistry, capacity, complexity, charging, environment, and application. The variety of battery chemistries available, combined with the variety of battery-powered applications, results in each battery application having specific, unique requirements pertinent to the specific battery application. However, there are basic requirements for all battery designs and applications, which are listed in section 4. Section 5 includes a description of hazards and controls and also includes requirements.

Jeevarajan, Judith A.↗
NASA NTRS1976

Space Telescope Optical Telescope Assembly/Scientific Instruments: Phase B - Preliminary Design and Program Definition Study: Volume 2A - Planetary Camera

Development of the F/48, F/96 Planetary Camera for the Large Space Telescope is discussed. Instrument characteristics, optical design, and CCD camera submodule thermal design are considered along with structural subsystem and thermal control subsystem. Weight, electrical subsystem, and support equipment requirements are also included.

Itek Optical Systems↗
NASA NTRS2026

A Modular Conjugate Heat Transfer Optimization Framework for Thermal Management of Electric Aircraft

Conjugate heat transfer (CHT) analysis and optimization is a powerful method for improving thermal management, as it simultaneously resolves the temperature distribution in both fluid and solid domains. This paper presents a modular, discrete adjoint-based CHT optimization capability integrated within the OpenMDAO/MPhys framework. A unique feature of the proposed framework is its flexibility to extend to multidisciplinary optimization, including aero-structural-thermal applications. The fluid domain is modeled using a finite-volume Computational Fluid Dynamics (CFD) solver, and the solid domain with a conduction heat transfer solver. A mixed Neumann-Dirichlet boundary condition is developed to enable full submersion of the solid geometry within the fluid domain, while ensuring consistent temperature and heat flux coupling at the CHT interface. Gradient-based optimization is performed; the gradients are efficiently computed using the discrete adjoint solvers implemented in DAFoam. To demonstrate the method, this paper considers two cases related to electric aircraft thermal management: a U-bend heat exchanger and an actively cooled battery pack. The U-bend case aims to minimize pressure loss while maximizing heat flux by changing the pipe geometry. The optimized design reduces pressure loss by 52.7% and increases total heat flux by 2.3%. In the battery pack case, a 3-by-3 cell configuration is cooled by ambient airflow, with constant heat generation prescribed in the cells. The battery casing shape serves as the design variable, and the objective function is a weighted sum of pressure loss and pack weight, subject to a maximum temperature constraint. The optimized design achieves a 44.6% reduction in pressure loss and a 1.5% reduction in weight, while satisfying the thermal constraint. To ensure the reliability of the optimized designs, this study validates coarse-mesh, steady-state predictions against fine-mesh unsteady simulations, demonstrating consistency within acceptable errors. This work demonstrates the potential of the developed framework to enable rapid, high-fidelity design of thermal management systems for electric aircraft.

heat transfer↗
NASA NTRS1976

Reanalysis of the Apollo Cosmic Gamma-Ray Spectrum in the 0.3- to 10-MeV Energy Region

Additional data obtained from the Apollo-16 and -17 missions, together with collateral calculations on background radiation effects, have enabled an improved subtraction of unwanted backgrounds from the diffuse cosmic gamma-ray data previously reported from Apollo-15. As a result, the 1- to 10-MeV spectrum is lowered significantly and connects smoothly with recent data at other energies. The inflections reported previously is much less pronounced and has no more than a 1.5-σ significance. Sky occultation by the Apollo-16 spacecraft shows the bulk of the 0.3-- to 1-MeV radiation to be diffuse. The analysis of spurious backgrounds points to important improvements for future experiments designed for this spectral region.

Gamma Rays↗
NASA NTRS1977

Reanalysis of the Apollo Cosmic Gamma-Ray Spectrum in the 0.3 to 10 Mev Energy Region

Additional data obtained from the Apollo 16 and 17 missions, together with collateral calculations on background radiation effects, have made possible an improved subtraction of unwanted backgrounds from the diffuse cosmic gamma ray data previously reported from Apollo 15. As a result, the 1 to 10 MeV spectrum is lowered significantly and connects smoothly with recent data at other energies. The inflection reported previously is much less pronounced and has no more than 1.5 sigma significance. Sky occultation by the Apollo 16 spacecraft shows the bulk of the 0.3 to 1 MeV radiation to be diffuse. The analysis of spurious backgrounds points to important improvements for future experiments designed for this spectral region. A light-weight satellite design can give a fourfold improvement in the signal to noise for such a measurement. Use of an anisotropic central crystal, which spins quickly compared with possible time variations in detector background, would enable sensitive limits to be set on galactic plane and point source contributions.

C S Dyer↗
NASA NTRS2026

Hybrid Thermally Efficient Core (HyTEC) Phase 1 3-Stage Compressor Rig Final Report - Unlimited Rights

The HyTEC Phase 1 3-Stage Compressor Rig project was conducted to mature and validate front-stage aerodynamic technologies in support of HyTEC Phase 2 and GEA’s Compact Core compressor. Building on the prior ERA Phase 2 Baseline Rig, GEA and NASA collaborated on the design and testing of the HyTEC rig, incorporating advanced technologies such as increased radius ratio, higher aerodynamic loading, and advanced casing treatment. The HyTEC test campaign leveraged similar design and instrumentation philosophy, test execution approach, and the same facility (NASA W-7) to enable clear comparison with the legacy ERA rig results. The HyTEC rig was designed to deliver benefits in efficiency, tip loading, operability, and aeromechanics, with success measured against defined TPMs that were anchored to the ERA baseline rig data.

Axial Compressors↗
NASA NTRS2018

International Space Station Lithium-Ion Battery Status

When originally launched, the International Space Station (ISS) primary Electric Power System (EPS) used Nickel-Hydrogen (Ni-H2) batteries to store electrical energy. The electricity for the space station is generated by its solar arrays, which charge batteries during insolation for subsequent discharge during eclipse. The Ni-H2 batteries were designed to operate for ten years at a 35 percent depth of discharge (DOD) maximum during normal operation in a Low Earth Orbit. For service beyond that period, upgraded Li-Ion Orbital Replacement Units (ORUs) were designed. These are the largest Li-Ion batteries ever utilized for a human rated spacecraft. With the oldest 12 Ni-H2 battery ORUs cycling since September 2006, the first set of six was replaced by Li-Ion batteries in December 2016; the second set of six is planned for replacement in September 2018. This paper will include an overview of the ISS Li-Ion battery system architecture, on-orbit status of the first 6 batteries, start up of the second 6 batteries, and the status of the Li-Ion cell and ORU life cycle testing.

International Space Station↗
NASA NTRS1990

The Hubble Space Telescope nickel-hydrogen battery design

Details are presented of the HST (Hubble Space Telescope) battery cell, battery package, and module mechanical and electrical designs. Also included are a summary of acceptance, qualification, and vibration tests and thermal vacuum testing. Unique details of battery cell charge retention performance characteristics associated with prelaunch hold conditions are discussed. Special charge control methods to minimize thermal dissipation during pad charging operations are summarized. This module design meets all NASA fracture control requirements for manned missions.

Nawrocki, D. E.↗
NASA NTRSDate not supplied

Fire-Resistant Textile Development for Exploration Vehicles With Enriched-Oxygen Cabin Environments

Material selection is a key part of the National Aeronautics and Space Administration (NASA) spacecraft fire safety management plan. Non-flammable textiles are necessary to ensure large-scale flame propagation events do not occur inside a spacecraft. An increased use of textiles and other softgood material is crucial to the pursuit of exploration spaceflight to reduce mass and volume. Exploration spaceflight missions benefit from enriched oxygen cabin environments (>21% O2) by allowing a reduced prebreathe protocol before Extravehicular Activity (EVA). However, materials become exponentially more flammable the higher the O2 levels become. Recent testing within the agency has revealed the lack of commercial-off-the-shelf (COTS) materials that can meet safety requirements in oxygen-enriched environments. Most of the fibers and textiles developed during Apollo (100% O2 cabin environment) and Skylab (>70% O2 cabin environment) are no longer commercially available due to those Programs ending and the discontinuation of raw materials or closure of the original manufacturers. As NASA returns to higher oxygen concentrations inside spacecraft, non-flammable textile development efforts have begun to meet the agency’s needs. This paper discusses those efforts including overall fire safety approach, priorities, interactions with industry, flammability testing and expected challenges.

Karim Aly↗
NASA NTRSDate not supplied

Harness Thermal Heat Loss Measurement for a Lunar Surface-Deployed LEMS Artemis III Payload

The Lunar Environment Monitoring Station (LEMS) is an autonomous, survive-the-lunar-night seismic suite to be deployed on the Lunar surface by the Artemis III crew and designed to operate continuously for two years. It will see the extremes of the Lunar south pole thermal environment where surface temperatures range from -200°C to +20°C and where nighttime duration is at least 354 hours. Given power and mass constraints, the thermal system is limited to 2.5 Watts of heat during the lunar night. The electrical harnessing named the Signal and Power Passthrough (SAPP) was designed to minimize heat loss while meeting power and signal integrity requirements. To mitigate risk due to uncertainty associated with the harnessing materials, routing, and tie-downs, a flight-like thermal conductance test was performed to measure the heat loss. The test methodology, results, and model correlation are presented.

TVAC↗
NASA NTRSDate not supplied

Harness Thermal Heat Loss Measurement for A Lunar Surface-Deployed LEMS Artemis III Payload

The Lunar Environment Monitoring Station (LEMS) is an autonomous, survive-the-lunar-night seismic suite to be deployed on the Lunar surface by the Artemis III crew and designed to operate continuously for two years. It will see the extremes of the Lunar south pole thermal environment where surface temperatures range from -200°C to +20°C and where nighttime duration is at least 354 hours. Given power and mass constraints, the thermal system is limited to 2.5 Watts of heat during the lunar night. The electrical harnessing named the Signal and Power Passthrough (SAPP) was designed to minimize heat loss while meeting power and signal integrity requirements. To mitigate risk due to uncertainty associated with the harnessing materials, routing, and tie-downs, a flight-like thermal conductance test was performed to measure the heat loss. The test methodology, results, and model correlation are presented.

Thermal↗
NASA NTRSDate not supplied

Harness Thermal Heat Loss Measurement for A Lunar Surface-Deployed LEMS Artemis III Payload

The Lunar Environment Monitoring Station (LEMS) is an autonomous, survive-the-lunar-night seismic suite to be deployed on the Lunar surface by the Artemis III crew and designed to operate continuously for two years. It will see the extremes of the Lunar south pole thermal environment where surface temperatures range from -200°C to +20°C and where nighttime duration is at least 354 hours. Given power and mass constraints, the thermal system is limited to 2.5 Watts of heat during the lunar night. The electrical harnessing named the Signal and Power Passthrough (SAPP) was designed to minimize heat loss while meeting power and signal integrity requirements. To mitigate risk due to uncertainty associated with the harnessing materials, routing, and tie-downs, a flight-like thermal conductance test was performed to measure the heat loss. The test methodology, results, and model correlation are presented.

TVAC↗
NASA NTRS2016

International Space Station Lithium-Ion Battery

The International Space Station (ISS) primary Electric Power System (EPS) currently uses Nickel-Hydrogen (Ni-H2) batteries to store electrical energy. The electricity for the space station is generated by its solar arrays, which charge batteries during insolation for subsequent discharge 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 ORU and cell life testing project. When deployed, they will be the largest Li-Ion batteries ever utilized for a human-rated spacecraft. This paper will include an overview of the ISS Li-Ion battery system architecture, the Li-Ion battery design and development, controls to limit potential hazards from the batteries, and the status of the Li-Ion cell and ORU life cycle testing.

battery↗
NASA NTRS1977

The standard 20 AH battery

The modular power system, which is the first intended use for the NASA standard battery, is basically a four foot by four foot by eighteen inch box which can handle a complement of three 20 ampere hour batteries or later on the intended use is for three 50 ampere hour batteries to be the full complement. The system is designed to be used as a plug on component on a multi mission modular spacecraft. It has as a design point a basically 1250 watt orbital average load. The way it breaks up in a near earth orbit it would be somewhere around 1,000 watts for everything except 10 minutes, and during any 10 minute period it may go up to a peak of 3,000 watt load. Features of the battery reviewed include criteria to store electrical energy, the battery package, the covers and cases, and electrolytes. The capacities expected are 90 percent, the average cell capacity for 24 C, 90 percent of the actual battery capacity of 19 C, and 85 percent of the actual 25 degree battery capacity at zero discharge voltage for 50 percent DOD new battery is in the vicinity expected or predicted of 26.4 volts.

Zollner, M. T.↗