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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 NTRS2026

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↗
NASA NTRS2026

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↗
NASA NTRS1995

The Design and Testing of the LSSIF Advanced Thermal Control System

The Life Support Systems Integration Facility (LSSIF) provides a platform to design and evaluate advanced manned space systems at NASA Johnson Space Center (JSC). The LSSIF Early Human Testing Initiative requires the integration of such subsystems to enable human occupancy of the 6 meter chamber for a 90 day closed volume test. The Advanced Thermal Control System (TCS) is an important component of the integrated system by supplying coolant to the subsystems within the chamber, such as the Air Revitalization System. The TCS incorporates an advanced high efficiency, heat pump to reject waste heat from the chamber to an external sink or 'lift' temperature that emulates a Lunar environment. The heat pump is the High Lift Heat Pump, developed by Foster-Miller, Inc., and is the main test article of the TCS. The heat pump prototype utilizes a non-CFC refrigerant in a design where the thermal requirements exceed existing terrestrial technology. These operating requirements provide a unique opportunity to design and test an advanced integrated thermal system and the associated controls. The design, control, and systems integration of the heat pump and the TCS also have terrestrial technology application. This paper addresses the design of the TCS and the heat pump, along with the control scheme to fully test the heat pump. Design approaches utilized in the LSSIF TCS are promoted for implementation in terrestrial thermal systems. The results of the preliminary thermal and fluid analyses used to develop the control of the thermal systems will also be discussed. The paper includes objectives for the 90 day human test and the test setup. Finally, conclusions will be drawn and recommendations for Earth design application are submitted.

Henson, Robert A.↗
NASA NTRS1982

Recent developments in thermal radiation system analyzer (Trasys)

Changes in the thermal radiation analyzer system (TRASYS) computer program are discussed. New capabilities were added while keeping intact the same data input structure. An overview of the program structure and general capabilities is given. Where appropriate, assessments are made of new features. The application of TRASYS peripheral programs and the importance they have in developing a totally integrated thermal analysis system are discussed. Form factor computations times were reduced approximately 40 percent, and the longer flux runs were reduced 50 percent when shadow tables were used.

Vogt, R. A.↗
NASA NTRS2004

A Selected Operational History of the Internal Thermal Control System (ITCS) for International Space Station (ISS)

The Internal Thermal Control System (ITCS) has been developed jointly by Boeing Corporation, Huntsville, Alabama and Honeywell Engines & Systems, Torrance, California to meet the internal thermal control needs for the International Space Station (ISS). The ITCS provides heat removal for the critical life support systems and thermal conditioning for numerous experiment racks. The ITCS will be fitted on a number of modules on the ISS. The first US Element containing the ITCS, Node 1, was launched in December 1998. Since Node 1 does not contain a pump to circulate the fluid it was not filled with ITCS fluid until after the US Laboratory Module was installed. The second US Element module, US Laboratory Module, which contains the pumps and all the major ITCS control hardware, was launched in February 2001. The third US Element containing the ITCS, the US Airlock, was launched in July 2001. The dual loop system of the ITCS is comprised of a lowtemperature loop (LTL) and a moderate-temperature loop (MTL). Each loop has a pump package assembly (PPA), a system flow control assembly (SFCA), a threeway mixing valve (TWMV), several rack flow control assemblies (RFCA), cold plates, pressure sensors, temperature sensors, pump bypass assembly (PBA) and a heat exchanger. In addition, the MTL has an additional TWMV, a payload regeneration heat exchanger (P/RHE) and a manual flow control valve (MFCV). The LTL has a service performance and checkout unit (SPCU) heat exchanger. The two loops are linked via one loop crossover assembly (LCA) providing cross loop capabilities and a single PPA, two-loop functionality. One important parameter monitored by the ground stations and on-orbit is the amount of fluid leakage from the ITCS. ISS fluid leakage is of importance since ITCS fluid is costly to re-supply, may be difficult to clean up in zero-g, and if uncontained could lead to equipment failures and potential hazards. This paper examines the nominal leakage observed over period of a year of on-orbit operation and compares this with analysis predictions. This paper also addresses the off-nominal leakage and a fluid transfer event causing significant changes in accumulator quantity.

Patel, Vipul P.↗
NASA NTRS1973

Thermal flux transfer system

A thermal flux transfer system for use in maintaining the thrust chamber of an operative reaction motor at given temperatures is described. The system is characterized by an hermetically sealed chamber surrounding a thrust chamber to be cooled, with a plurality of parallel, longitudinally spaced, disk-shaped wick members formed of a metallic mesh and employed in delivering a working fluid, in its liquid state, radially toward the thrust chamber and delivering the working fluid, in its vapor state, away from the nozzle for effecting a cooling of the nozzle, in accordance with known principles of an operating heat pipe.

Freggens, R. A.↗
NASA NTRS1975

Thermal control extravehicular life support system

The results of a comprehensive study which defined an Extravehicular Life Support System Thermal Control System (TCS) are presented. The design of the prototype hardware and a detail summary of the prototype TCS fabrication and test effort are given. Several heat rejection subsystems, water management subsystems, humidity control subsystems, pressure control schemes and temperature control schemes were evaluated. Alternative integrated TCS systems were studied, and an optimum system was selected based on quantitative weighing of weight, volume, cost, complexity and other factors. The selected subsystem contains a sublimator for heat rejection, bubble expansion tank for water management, a slurper and rotary separator for humidity control, and a pump, a temperature control valve, a gas separator and a vehicle umbilical connector for water transport. The prototype hardware complied with program objectives.

Source record↗
DOE OSTI2023

Physics-constrained fault diagnosis framework for monitoring a multi-component thermal hydraulic system

A method for diagnosing faults includes receiving a system description of a thermal hydraulic system, the system description indicating a plurality of components and sensors. The method also includes constructing, based on physical conservations laws and using the system description, a plurality of physics-based models for the plurality of components, each of the plurality of physics-based models including unknown parameters. The method further includes receiving historical measurements and calibrating the physics-based models by calculating the unknown parameters of each of the physics-based models using the historical measurements to produce calibrated models. The method also includes receiving sensor measurements of the sensors, and calculating residuals corresponding to differences between measurements predicted by the plurality of calibrated models and the sensor measurements. The method also includes determining, based on the calculated residuals, a fault of a component or a sensor, and generating an alert indicating the fault.

Nguyen, Tat Nghia↗
DOE OSTI2021

Performance of Compact Pulsed Thermal Imaging System for In-Service Applications. Pulsed thermal tomography nondestructive examination of additively manufactured reactor materials and components

Additive manufacturing (AM) is an emerging method for cost-efficient fabrication of complex topology nuclear reactor parts from high-strength corrosion resistance alloys, such as stainless steel and Inconel. AM of metallic structures for nuclear energy applications is currently based on laser powder bed fusion (LPBF) process, which has the capability of melting metallic powder and net shaping the structures with relatively high precision. Some of the challenges with using LPBF method for nuclear manufacturing include the possibility of introducing pores into metallic structures. Integrity of AM structures needs to be evaluated nondestructively because material flaws could lead to premature failures due to creep in high temperature nuclear reactor environment. Currently, there exist limited capabilities to evaluate actual AM structures nondestructively. Pulsed Thermography (PT) imaging provides a capability for non-destructive evaluation (NDE) of sub-surface defects in arbitrary size structures. The PT method is based on recording material surface temperature transients with infrared (IR) camera following thermal pulse delivered on material surface with flash light. The PT method has advantages for NDE of actual AM structures because the method involves one-sided non-contact measurements and fast processing of large sample areas captured in one image. The data cube of PT measurements consists of surface temperature taken at sequential time intervals T(x,y,t). Material defects can be detected either by analyzing the thermograms T(x,y,t) data cube, or by using thermal tomography (TT) algorithm to obtain 3D spatial reconstruction of thermal effusivity e(x,y,z). To reduce the cost and enable in-service NDE in spatially constrained environment, it is highly desirable to develop PT with compact and inexpensive IR camera. Following initial qualification of an AM component for deployment in a nuclear reactor, a compact PT system can also be used for in-service nondestructive evaluation (NDE) applications. However, data cube obtained with PT based on compact IR camera suffers from strong thermal noises and loss of features due to relatively low sampling rate. In this report we describe two unsupervised machine learning (ML) algorithms for enhancement of PT images obtained with compact IR camera. In one approach, we introduce Sparse Coding Discrete Cosine Transform (SC/DCT) algorithm to remove additive white Gaussian noise (AWGN) from spatial thermal effusivity reconstructions. In another approach we introduce a Spatial Temporal Denoised Thermal Source Separation (STDTSS) ML algorithm to process thermograms. The STDTSS algorithm consists of spatial and temporal denoising using Gaussian and Savitzky–Golay filtering, followed by the matrix decomposition using Principal Component Analysis (PCA), and Independent Component Analysis (ICA) to automatically detect flaws. In the work described in this report, we constructed a compact PT system using a relatively small and low-cost FLIR A65 camera, consisting on uncooled microbolometer detector. Performance of SC/DCT algorithm was demonstrated on enhancing TT images of Inconel 718 AM plate. Performance of the STDTSS methods was investigated using thermography data obtained from imaging stainless steel 316L specimens produced with LPBF method with imprinted calibrated porosity defects.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS1985

Optimization of the NiCrAl-Y/ZrO-Y2O3 thermal barrier system

The effects of bond and thermal barrier coating compositions, thicknesses, and densities on air plasma spray deposited Ni-Cr-Al-Y/ZrO2-Y2O3 life were evaluated in cyclic furnace oxidation tests at temperatures from 1110 to 1220 C. An empirical relation was developed to give life as a function of the above parameters. The thermal barrier system tested which had the longest life consisted of Ni-35.0 wt% Cr-5.9 wt% Al-0.95 wt% Y bond coating and ZrO2-6.1 wt% Y2O3 thermal barrier coating.

Stecura, S.↗
NASA NTRS1979

Thermal power systems small power systems application project: Siting issues for solar thermal power plants with small community applications

The siting issues associated with small, dispersed solar thermal power plants for utility/small community applications of less than 10 MWe are reported. Some specific requirements are refered to the first engineering experiment for the Small Power Systems Applications (SPSA) Project. The background for the subsequent issue discussions is provided. The SPSA Project and the requirements for the first engineering experiment are described, and the objectives and scope for the report as a whole. A overview of solar thermal technologies and some technology options are discussed.

Holbeck, H. J.↗
NASA NTRS1986

Optimization of the Ni-Cr-Al-Y/ZrO2-Y2O3 thermal barrier system

The effects of bond and thermal barrier coating compositions, thicknesses, and densities on air plasma spray deposited Ni-Cr-Al-Y/ZrO2-Y2O3 life were evaluated in cyclic furnace oxidation tests at temperatures from 1110 to 1220 C. An empirical relation was developed to give life as a function of the above parameters. The thermal barrier system tested which had the longest life consisted of Ni-35.0 wt pct Cr-5.9 wt pct Al-0.95 wt pct Y bond coating and ZrO2-6.1 wt pct Y2O3 thermal barrier coating.

Stecura, S.↗
NASA NTRS1988

Long-term performance of the passive thermal control systems of the IRAS spacecraft

Degradation of passive thermal control systems in space is a matter of serious concern and has been observed in many missions. The performance of the passive thermal control systems of the Infrared Astronomical Satellite (IRAS) over a period of three years is reported here. An exterior temperature of 200 K and a sunshade temperature of approximately 100 K were maintained over this period without significant degradation. The temperature of the telescope contained in the IRAS cryostat was also observed for two years after expenditure of the helium cryogen. It remained at 100 K with no degradation.

Mason, P. V.↗
NASA NTRS1990

Advanced automation of a prototypic thermal control system for Space Station

Viewgraphs on an advanced automation of a prototypic thermal control system for space station are presented. The Thermal Expert System (TEXSYS) was initiated in 1986 as a cooperative project between ARC and JCS as a way to leverage on-going work at both centers. JSC contributed Thermal Control System (TCS) hardware and control software, TCS operational expertise, and integration expertise. ARC contributed expert system and display expertise. The first years of the project were dedicated to parallel development of expert system tools, displays, interface software, and TCS technology and procedures by a total of four organizations.

Dominick, Jeff↗
NASA NTRS1983

Systems approach to walk-off problems for dish-type solar thermal power systems

'Walk-off' in a dish-type solar thermal power system is a failure situation in which the concentrator remains fixed while the spot of concentrated sunlight slowly moves across the face of the receiver. The intense local heating may damage the receiver and nearby equipment. Passive protection has advantages in minimizing damage, but in a fully passive design the receiver must be able to withstand full solar input with no forced fluid circulation during the walk-off. An active walk-off emergency subsystem may include an emergency detrack or defocus mechanism or sun-blocking device, emergency power, sensors and logic to detect the emergency and initiate protective action, and cooling or passive protection of emergency and non-emergency components. Each of these elements is discussed and evaluated in the paper.

Jaffe, L. D.↗
NASA NTRS2010

Damage Detection/Locating System Providing Thermal Protection

A damage locating system also provides thermal protection. An array of sensors substantially tiles an area of interest. Each sensor is a reflective-surface conductor having operatively coupled inductance and capacitance. A magnetic field response recorder is provided to interrogate each sensor before and after a damage condition. Changes in response are indicative of damage and a corresponding location thereof.

Woodard, Stanley E.↗