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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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1,254 records · Page 17

Failure Modes of Reduced-Order Orbit Determination Filters and Their Remedies

Ways in which failure can occur in reduced-order, orbit determination filter, error covariance calculations are discussed. In the context of this article, reduced-order filters denote nonoptimal filters which include fixed levels of uncertainty in some parameters of the measurement models or in the spacecraft dynamical model which are not explicitly estimated in the filter equations. Failure is defined as an increase in the orbit determination covariance with the addition of data or as an unreasonable growth in the covariance with time, i.e., nonasymptotic behavior of the covariance. Some simple, known cases of failure are discussed along with their traditional remedies. In addition, more modern remedies are discussed which are currently under development at the Jet Propulsion Laboratory. The article first describes the known problems of reduced-order filters when they are employed for orbit determination, and their traditional remedies. Then, having defined these, the relevancy and desirability of the more modern remedies are made apparent.

D J Scheeres

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

Spike-Nosed Bodies and Forward Injected Jets in Supersonic Flow

The paper contains new numerical simulation and experimental test results of blunt body drag reduction using thin spikes mounted in front of a body and one- or two-phase jets injected against a supersonic flow. Numerical simulations utilizing the NASA CFL3D code were conducted at the Hampton University Fluid Mechanics and Acoustics Laboratory (FM&AL) and experimental tests were conducted using the facilities of the IM/MSU Aeromechanics and Gas Dynamics Laboratory. Previous results were presented at the 37 t h AIAA/ASME/SAE/ASEE Joint Propulsion Conference. Those results were based on some experimental and numerical simulation tests for supersonic flow around spike-nosed or shell-nosed bodies, and numerical simulations were conducted only for a single spike-nosed or shell-nosed body at zero attack angle, alpha=0 o . In this paper, experimental test results of gas, liquid and solid particle jet injection against a supersonic flow are presented. In addition, numerical simulation results for supersonic flow around a multiple spike-nosed body with non-zero attack angles and with a gas and solid particle forward jet injection are included. Aerodynamic coefficients: drag, C D , lift, C L , and longitudinal momentum, M z , obtained by numerical simulation and experimental tests are compared and show good agreement.

M Gilinsky

Thermal Analysis on Large Format Lithium-Ion Batteries in Thermal Runaway

Lithium-ion (Li-ion) batteries can deliver electrical power across a large range of applications, and large format versions of these batteries are common in aerospace for their low mass and energy dense properties. Li-ion cells usage has increased as they are more power dense than fuel cells and have overall higher performance over lead-acid/NiCd batteries. However, Li-ion cells can experience Thermal Runaway (TR) via electro-chemical, mechanical, or thermal abuse. TR is a phenomenon where the stored energy in a cell is rapidly released along with vented gases and other effluents. A cell is generally determined to be in TR if its internal heat generation has surpassed its ability to dissipate that heat. If a Li-ion cell enters TR, propagation within the battery may occur. Propagation is the chain reaction that can occur to nearby cells due to a cell that has entered TR initially. Understanding a battery’s susceptiveness to propagation is necessary to evaluate risks associated with TR phenomenon. To determine if a battery is designed in a sufficient manner to prevent battery propagation if single cell TR occurs, testing and thermal analysis of the battery must be conducted. The presentation for TFAWS 2026 will cover considerations for battery TR thermal analysis, such as: testing methods, influences on the cells, failure mechanisms, and TR parameters. This presentation will include a walkthrough of an example battery TR thermal analysis, and the results thereof.

Lithium Ion Batteries

Hybrid Modeling Study on Grain Evolution in the Metal Welding Process and Its Potential Lunar Application

Metal is most commonly used structural material in a wide range of spacecraft, and welding is the principal method for joining metal components into functional systems. However, conducting welding experiments under extreme environments—such as microgravity or vacuum conditions in space—is prohibitively expensive and experimentally challenging. To overcome these limitations, multi-physics computational welding models provide a cost-effective and versatile alternative. In this work, the authors have developed a coupled thermal (fluid) microstructure simulation framework to model metal welding under varying gravity conditions. The framework integrates a mixed-mode heat transfer formulation (conduction, convection, and radiation) with molten pool fluid dynamics, enabling accurate prediction of temperature fields and weld-pool geometry. A grain growth model is further incorporated to capture the spatial and temporal evolution of microstructure, including grain size distribution and morphological transitions during solidification. This approach provides detailed insight into molten pool evolution and grain-level microstructure development throughout the welding process. By explicitly parameterizing environmental conditions, the model supports extrapolation to off-Earth manufacturing scenarios such as welding on the lunar surface. Tantalum—chosen in this study due to its high melting point, oxidation resistance, and mechanical stability at elevated temperatures—serves as the material system for model demonstration. Beyond Tantalum, the integrated multi-physics framework offers broad applicability for predictive welding simulations of various structural and refractory metals or alloys used in extreme terrestrial or extraterrestrial environments.

kinetic Monte Carlo (SPPARKS)

Spike-Nosed Bodies and Forward Injected Jets in Supersonic Flow

The paper contains new numerical simulation and experimental test results of blunt body drag reduction using thin spikes mounted in front of a body and one- or two-phase jets injected against a supersonic flow. Numerical simulations utilizing the NASA CFL3D code were conducted at the Hampton University Fluid Mechanics and Acoustics Laboratory (FM&AL) and experimental tests were conducted using the facilities of the IM/MSU Aeromechanics and Gas Dynamics Laboratory. Previous results were presented at the 37th AIAA/ASME/SAE/ASEE Joint Propulsion Conference. Those results were based on some experimental and numerical simulation tests for supersonic flow around spike-nosed or shell-nosed bodies, and numerical simulations were conducted only for a single spike-nosed or shell-nosed body at zero attack angle, alpha = 0 degrees. In this paper, experimental test results of gas, liquid and solid particle jet injection against a supersonic flow are presented. In addition, numerical simulation results for supersonic flow around a multiple spike-nosed body with non-zero attack angles and with a gas and solid particle forward jet injection are included. Aerodynamic coefficients: drag, C (sub D), lift, C(sub L), and longitudinal momentum, M(sub z), obtained by numerical simulation and experimental tests are compared and show good agreement.

M Gilinsky

X-Ray Absorption Spectroscopy in High Temperature Oxidation of Metals and Alloys

An experimental technique is described that allows for the joint study of the kinetics and of the oxide structure during the high temperature oxidation of metal surfaces. Oxygen is supplied at the metal through an electrochemical oxygen pump and the oxygen pressure, at the metal surface, is measured during oxidation by a YSZ (yttria stabilized zirconia) oxygen sensor. XAS (x-ray absorption spectroscopy) is performed in fluorescence mode at the cation K edge and after each oxidation step. An appropriate analysis of the XAS spectra could provide information on both the oxidation kinetics and oxide structure. Experimental data on the high temperature oxidation of nickel, cobalt, and Fe(64%)Ni(36%) alloy, at low oxygen pressure, are reported and analyzed according to the proposed data reduction. These results indicate the presented technique to be particularly suitable for studying the hot corrosion of oxide film too thick for common surface spectroscopy (AUGER, ESCA) and too thin for conventional thermogravimetric technique.

Daniele Gozzi

New Trends in Coatings Developments for Turbine Blades: Materials Processing and Repair

Turbine engines for aeronautic applications now have to face strenuous requirements concerning not only operating performances but also reliability and repairability. This evolution of the specifications induces important consequences regarding the choice and the design of turbine blade protective coatings. This paper presents several key features concerning the deposition techniques and the real-life behavior of such coatings: (1) complex aluminides well suited to the protection against high temperature oxidation and hot corrosion of directionally solidified nickel-base superalloy turbine blades; (2) ceramic coatings used as thermal barriers - they have to exhibit both high resistance to thermomechanical fatigue and adequate smoothness; (3) processing techniques for thermal barriers, including plasma spraying, electron beam physical vapor deposition and plasma enhanced chemical vapor deposition; and (4) blades and coatings repair techniques.

S Alpérine

High-Order Methods in NASA’s Next Generation of Computational Fluid Dynamics Tools

The missions of the National Aeronautics and Space Administration (NASA) routinely produce unique requirements and challenges for development and application of Computational Fluid Dynamics (CFD) methods. NASA presently embodies four distinct Mission Directorates: Aeronautics Research, Exploration Systems, Science, and Space Operations. These missions generate requirements for systems that operate in a wide variety of environments. They range from the high-speed flight of aerodynamically optimized vehicles operating in the earth’s atmosphere to spacecraft designed for missions that don’t favor aerodynamic optimization, some operating in the atmosphere of planets and planetary moons such as Mars and Venus or Saturn’s moon Titan. Systems supporting these vehicles, such as rocket and jet propulsion, reaction control systems, fluid and thermal transfer systems, etc. can also generate their own unique set of flow phenomena that challenge today’s CFD methodology. Through the NASA Engineering and Safety Center (NESC), NASA annually conducts state-of-the-discipline assessments in fifteen distinct engineering disciplines. These assessments are performed by the NASA Technical Fellows that lead Technical Discipline Teams (TDT) of recognized experts in these fifteen areas. In the Aerosciences discipline, three topics have been identified as the top challenges for the discipline: aero-plume interaction prediction, unsteady separated flows, and aerothermodynamic prediction. These challenge areas are defined by the Agency’s high-risk projects and problems on which the NESC is requested to perform independent testing, analysis, and assessments. When viewed as a whole, these tests, analyses, and assessments provide a clear view of the recurring technical challenges facing Agency engineers and researchers and can be used to guide future research and technology development. The present state-of-the-art in the application of CFD at NASA is the use of Reynolds-Averaged Navier- Stokes (RANS) solvers, primarily executed in a steady-state mode of operation. In isolated cases, Unsteady RANS (URANS) solvers have been employed when steady RANS solutions produce poorly converging or oscillating results or in cases, such as aeroelastic analysis, which require unsteady aerodynamic simulation. For most traditional external and internal aerodynamic flows, structured overset grids or unstructured grids are employed to minimize geometric modeling and grid generation times. Grid adaptation, primarily as a series of coarse-grain intermediate processing steps is also seeing use on particularly complex flow problems and configurations. In the case of aerothermodynamic flows, engineers have been forced to continue to employ structured grid techniques as the present unstructured grid methodology has proven inadequate in the prediction of surface heating. In the area of aero-plume interaction modeling, two-gas, frozen chemistry simulation is generally the state-of-the- art, with some production solvers capable of predicting flows with only a single gas component. Prediction of flows falling into the afore-mentioned top Aerosciences technical challenges have severely stressed the present state-of-the-art in CFD prediction and for some problems, such as unsteady separated flows and aero-plume interaction cases, engineers have begun employing Large Eddy Simulation (LES) and Hybrid RANS/LES techniques. In some isolated aero-propulsion interaction cases, chemically reacting flow simulations have been applied. These methods are highly evolutionary and engineers have little experience in their application, so they cannot be heavily relied upon in today’s application environment. Therefore, this leads one to muse over which numerical technologies will be included in the CFD tools that will be employed 30 years in the future. This presentation will describe specific technical problems that have stressed NASA’s traditional CFD methods to their breaking point and will link these issues to the Agency’s top Aerosciences technical challenges. The discussion will then shift to the characteristics of future CFD solvers that will be required to attack these challenges and how these characteristics differ from the present state-of-the- art. High-order methods certainly appear to have a place in the development of future CFD tools and some of the physical characteristics of our most challenging problems suggest that high-order methods are the only way to effectively solve them. But there are some relatively severe implementation issues that face these methods, particularly in the area of general applicability and robust operation as an engineering tool. Desired characteristics of next-generation CFD solvers will be discussed and the author’s view of which emerging numerical technologies might be employed to address these attributes will also be presented

David M Schuster

Life test of 50 AH NiH2 battery

Life cycle testing on a battery is reported. The cells were built in 1975, put into battery in 1976, and flown in 1977 in low Earth orbit.

Warnoc, D. H.

Discrete Rotational Energy for Polyatomic Molecules in Direct Simulation Monte Carlo

Accurate prediction of aerothermodynamic loads in thermal non-equilibrium flows requires precise modeling of internal energy exchange. While previous direct simulation Monte Carlo frameworks have successfully implemented discrete rotational energy models for diatomic species, the treatment of polyatomic molecules has traditionally relied on continuous energy assumptions that break down at low temperatures and neglect critical high-temperature corrections. This study extends the discrete rotational energy models of Boyd and Gimelshein to fully encompass polyatomic molecules. The proposed framework implements quantized rotational energy level sampling for linear, spherical, and symmetric/asymmetric top rotors. Crucially, the model incorporates centrifugal distortion to address the limitations of the rigid-rotor assumption at hypersonic temperatures, and accounts for nuclear spin parity, which dictates the permissible rotational states and macroscopic specific heats at low temperatures. The model is verified through equilibrium sampling procedures, demonstrating agreement with theoretical quantum Boltzmann distributions and accurately reproducing thermophysical properties across a wide range of temperatures.

DSMC

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

Aerodynamic Performance and Acoustic Impacts of Varying Tip Speeds and Tripping Conditions on Small Rotors in an Anechoic Hover Chamber

Performance and acoustic measurements were taken in a hover chamber for various optimum hovering rotors (OPT2) and a commercial-off-the-shelf (COTS) rotor. A total of 10 rotors are included in this report, all of which have two blades and a tip radius of 0.1905 m (7.5 in.). For the OPT2, results for three additive manufacturing methods of fabrication are presented: stereolithography(SLA) using Accura Xtreme, SLA using FormLabs 10K resin, and selective laser sintering (SLS) using mineral-filled PA12 nylon material. All but one set of rotors were designed with a trailing edge bluntness that is 3% of the chord length, and one set was designed with a bluntness that is 1% of the chord length. Spanwise boundary layer trips were applied to the SLA, FormLabs and COTS rotors. Performance comparisons between untripped and tripped configurations demonstrate the impact of boundary layer state on rotor efficiency. Acoustic results, including periodic and broadband noise components, are presented. The effects of tripping these rotors near the leading edge are also presented. For some of the rotors, acoustic spectra of tip speed sweeps are presented to show how the frequency content changes with tip speed. Amplitude and frequency scaling methods are used to collapse broadband spectra at various tip speeds towards a unified curve. These findings contribute to the understanding of small rotor aeroacoustics and provide valuable datasets for computational model validation in urban air mobility applications.

eVTOL

Surprisingly Enriched CO and CH4 in Halley-type Comet 13P/Olbers: Clues to Its Interstellar Heritage

The native ice composition of Halley-type Comet 13P/Olbers (hereafter 13P) was measured post-perihelion, on UT 2024 August 16 using iSHELL, the 1–5 μm cross-dispersed, high-resolution facility spectrograph at the NASA InfraRed Telescope Facility. At that time, the heliocentric distance (Rh) of 13P was 1.37 au and the geocentric distance (Δ) was 1.99 au. Using a slit that delivered spectral resolving power RP λ/Δλ 4.5 × 104, two instrument settings targeted rovibrational emissions of seven parent molecules released into the coma through sublimation of ices in the nucleus. These settings provided broad and contiguous or nearly contiguous spectral coverage, one simultaneously measuring H2O, CO, and OCS, and the other simultaneously measuring CH4, C2H6, CH3OH, and H2CO. Meaningful abundances were obtained for all seven species. Our study revealed substantial enrichments of CO and CH4, the two most volatile species systematically targeted at IR wavelengths in comets. Relative to their respective mean abundance ratios among measured comets from the Oort cloud reservoir, CO in 13P was enriched by a factor of about six and CH4 was enriched by a factor of about three. Together with near-average abundances measured for CH3OH and C2H6, this suggests large endowments of CO and CH4 on interstellar grains, yet it could indicate inhibited surface chemistry on the pre-cometary grains subsequently contained in the nucleus or 13P. Assuming that this represents the primordial composition of 13P, it could reflect very low temperatures in its natal environment (∼10 K or lower).

Michael A Disanti

Degradation of optical components in a space environment

The objective of the Phillips Laboratory (PL) Long Duration Exposure Facility (LDEF) experiment is to determine the adverse effects of the natural space environment on laser optical component and coating materials. The LDEF experiment provides a unique opportunity for the study of optical material response to an extended low earth orbit space exposure. The PL samples consist of 10 sets of the six materials each. The materials are uncoated fused silica, magnesium fluoride coated fused silica, uncoated molybdenum, molybdenum coated with chromium, silver and thorium fluoride, diamond turned copper, and diamond turned nickel plated copper. Performance degradation will be correlated to establish trends between sample location, duration of exposure, atomic oxygen exposure and other space environmental conditions. This paper discusses the results of the tests thus far performed on the LDEF samples and the plans for the future.

Linda L. Dehainaut

A Machine Learning Framework for Error Compensation in Radiative Transfer Calculations

Radiative heat transfer influences the amount of heat flux transferred to the surface of the hypersonic vehicle, which is essential to evaluate the performance of thermal protection systems. The radiative heat flux is found to be computationally prohibitive while accounting for the variation in spatial, angular, and spectral domains. A new methodology has been recently developed to alleviate the cost of computation in the spectral domain by constructing flow-agnostic reduced-order models (ROMs). The developed spectral ROM databases provide grouping strategies that account for non-equilibrium absorption and emission as well as interaction between disparate species due to spectral overlap in associated radiative processes. However, the developed ROMs need to be optimized for a specific combination of interacting gas species and would need to re-calibrated in case individual species are added/omitted. In this work, we use various machine learning (ML) techniques to approximate the radiative intensities determined by a ROM optimized for a specific gas mixture. The ML model relies on the ROM databases developed for a single species which ignores any spectral overlap. Thus, radiation evaluation starts with a simple summation of radiative intensities predicted using these non-calibrated ROMs for the contributing species. The ML framework then provides a correction to account for the interplay in the frequency, i.e., emission of photons by one species and absorption by another, and yields mixture-specific radiation fields. Once trained on the individual ROM databases, the ML framework offers instantaneous corrections that serves as a time/cost effective alternative to the optimization of ROMs for a specific gas mixture. The ML framework is trained on both the high fidelity and ROM evaluated line of sight (LOS) data from Orion, Stardust, and FIRE II cases to obtain a general purpose correction model for earth re-entry scenarios when radiation contributions from both atomic nitrogen and atomic oxygen are considered. A geometric length scale parameter is used in the training process to account for errors introduced in the ROM databases as a consequence of high optical thickness. The efficacy of the ML framework is underscored through extensive analysis of train and test errors with respect to all the re-entry scenarios. The applicability of such an ML framework was further corroborated by embedding it in a state-of-the-art US3D - NERO system for determining the radiative heat flux transferred to the hypersonic vehicle surface.

Radiation

Thermal Performance of Common Bulk-Fill Cryogenic Insulation Materials in Helium and Hydrogen Background Gases

Maritime shipping of vast quantities of liquid hydrogen (LH 2 ) will be necessary to facilitate a global hydrogen ecosystem; with some studies estimating volumes up to 172,000 m 3 for individual tanker ships, and requiring stationary storage tanks at terminals of 50,000 m 3 to 100,000 m 3 —ten to fifteen times larger than the current largest tank, located at launch pad B at NASA Kennedy Space Center (KSC). Such a radical scale-up will push the boundary of traditional, vacuum-insulated tank designs. Hence, a potential need exists for non-vacuum solutions, which necessitates exploring the thermal performance of insulation materials in non-condensable background gasses at LH 2 temperatures, namely helium and hydrogen. Testing of two bulk-fill insulation materials common to large LH 2 storage tanks, perlite and glass bubbles, in helium and hydrogen was recently conducted by the Cryogenics Test Laboratory at KSC using the Cryostat-100 liquid nitrogen boiloff calorimeter per the ASTM C1774 standard methodology. Effective thermal conductivity (k e ) and heat flux (q) results for each insulation/gas combination are presented across the full vacuum range, as well as thermal profiles through the insulation thickness between 78 K and 293 K.

A M Swanger

Off‑World Additive Manufacturing - Augmenting NASA‑STD‑6030

This slide presents a summary for a soon to be released white paper on augmenting NASA-STD-6030 for off-world manufacturing. It examines the driving need for in-space manufacturing and its corresponding risks, challenges, potential solutions, and technology development needed to qualify a process.

NASA-STD-6030