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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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377 records · Page 21
All sourcesNASA NTRSDOE OSTI
NASA NTRS2024

Characterization of Low-Velocity Impact Damage in Toughened Non-Crimp Fabric Laminates

The damage response of resin-infused composites was investigated using quasi-static indentation (QSI) and instrumented drop-weight impact testing. The test specimens were composed of six layers of non-crimp fabrics where each layer contained +45°, 90°, −45°, and 0° plies. The goals of the testing were to identify damage responses that may differ from traditional thermoset materials and provide damage characterization data to evaluate current damage prediction analyses and aid improvements to current damage models. The damage was characterized using X-ray computed tomography (CT) and ultrasonic testing (UT). Incremental QSI loading was used on a single specimen to investigate damage growth in nine steps at progressively higher loads. Realtime acoustic emission data were used to determine the unloading points. Unlike typical thermoset composites, the force-displacement was smooth and showed no obvious indications of damage. The primary damage consisted of large lines of fiber fracture on the plies near the impact surface and delaminations through the thickness. Nine specimens were impacted at nominal impact energies of 25 ft-lbs, 30 ft-lbs, and 35 ft-lbs. The force histories at each energy followed nearly identical paths. Again, no obvious signs of damage were observed in any of the force histories. The general damage response in the dynamic tests was similar to the QSI-loaded specimens. However, repeat specimens impacted with a given impact energy showed variations in the damage. Some characteristics of the damage response were different than those typically observed in thermoset composites and will need to be evaluated using current analysis methods.

Composite Materials↗
NASA NTRSDate not supplied

The Effect of Impingement Angle on Bipropellant Thruster Plume Degradation of Spacecraft Materials

Unburned and partially combusted liquid propellant present in bipropellant thruster plumes can contaminate and damage external spacecraft materials. Microscopic impact features due to high-speed droplet impacts have been observed on space shuttle flight experiments and International Space Station (ISS) returned flight hardware. Analytical results have shown that particle impingement angle greatly affects surface damage, with normal impacts being the most severe and highly oblique impacts being more benign. The effect of thruster plume impingement angle on material degradation has now been further studied following a bipropellant thruster plume test performed at the high-vacuum plume test facility for chemical thrusters at DLR Göttingen, STG-CT. Several spacecraft material samples were exposed to the freely expanding pulsed thruster plume at a range of impingement angles (from 0 to 75 deg). Results of post-test evaluations and potential spaceflight applications are summarized.

Gateway↗
NASA NTRSDate not supplied

Characterization of Low-Velocity Impact Damage in Toughened Non-Crimp Fabric Laminates

The damage response of resin-infused composites was investigated using quasi-static indentation (QSI) and instrumented drop-weight impact testing. The test specimens were composed of six layers of non-crimp fabrics where each layer contained +45°, 90°, −45°, and 0° plies. The goals of the testing were to identify damage responses that may differ from traditional thermoset materials and provide damage characterization data to evaluate current damage prediction analyses and aid improvements to current damage models. The damage was characterized using X-ray computed tomography (CT) and ultrasonic testing (UT). Incremental QSI loading was used on a single specimen to investigate damage growth in nine steps at progressively higher loads. Realtime acoustic emission data were used to determine the unloading points. Unlike typical thermoset composites, the force-displacement was smooth and showed no obvious indications of damage. The primary damage consisted of large lines of fiber fracture on the plies near the impact surface and delaminations through the thickness. Nine specimens were impacted at nominal impact energies of 25 ft-lbs, 30 ft-lbs, and 35 ft-lbs. The force histories at each energy followed nearly identical paths. Again, no obvious signs of damage were observed in any of the force histories. The general damage response in the dynamic tests was similar to the QSI-loaded specimens. However, repeat specimens impacted with a given impact energy showed variations in the damage. Some characteristics of the damage response were different than those typically observed in thermoset composites and will need to be evaluated using current analysis methods.

Composite Materials↗
NASA NTRSDate not supplied

AI-Enhanced Computational Tools for Entry Systems Modeling

To advance the understanding of complex atmospheric entry phenomena, NASA’s Entry Systems Modeling (ESM) team [1] has developed high-fidelity computational tools addressing multiscale challenges, from material microstructures to full-scale heatshield response. This abstract highlights a subset of ESM tools, focusing on AI integration to enhance workflows and predictive modeling. - PuMA [2] computes effective material properties from high-resolution micro-CT scans, supporting TPS analysis for NASA missions. - TomoSAM [3] automates 3D tomography dataset segmentation for PuMA using the Segment Anything Model, reducing manual effort and improving accuracy. - PATO [4] models porous reactive materials under extreme conditions, with advancements such as unified solvers, mechanical erosion, and TPS coatings for NASA missions. - arcjetCV [5] employs deep learning to analyze arc jet test footage, measuring recession rates, shape changes, and shock standoff distances, bridging simulations, and experiments to reveal TPS ablation behavior. - ARCHeS [6] simulates arc heater plasma flows, modeling turbulence, radiation, and electromagnetic interactions to optimize arc heater performance, validate TPS under extreme conditions, and serve as a foundation for developing digital twins of arc heater facilities. - SPARTA [7] simulates rarefied hypersonic flows and gas-surface interactions for planetary entry missions, leveraging GPU architectures for scalable and efficient aerothermal and ablation analyses. AI-driven solutions, such as deep learning segmentation, have streamlined workflows in ESM tools and still hold significant potential to further accelerate processes and enhance automation in entry systems modeling. [1] Haskins, J.B. (2023), [2] Ferguson, J.C. (2018), [3] Meurisse, J.B.E. (2018), [4] Semeraro, F. (2023), [5] Quintart, A. (2024) [6] Meurisse, J.B.E. (2022), [7] Plimpton, S.J. (2019)

Predictive Modeling↗
NASA NTRSDate not supplied

Investigation of Lunar-Inspired Geopolymer Concrete Formulations Mixed and Cured in Microgravity on the International Space Station (ISS)

The research outlined in this presentation investigates the use of various lunar regolith simulants in geopolymer lunar concrete mixes mixed and cured on the International Space Station (ISS). The motivation for this work is to study the effects of gravity on the microstructure of alkali-activated materials cured with heat, and to develop materials for the construction of long-term infrastructure on the lunar surface with in-situ resource utilization (ISRU). ISRU for construction materials reduces the cost and mass of payloads related to lunar construction. The advantage of geopolymer concrete as opposed to traditional portland cement concrete is that water acts as a medium for the polymerization reaction and leaves the system throughout the process, reducing its demand. Twelve samples of lunar regolith simulant and a solution composed of sodium hydroxide and sodium silicate were sent to the ISS. The three simulants were OPRH2N, OPRL2N, and JSC-1AF, using only particles less than 53 µm in diameter to increase reactivity of the simulant. Simulant to solution ratios were determined by workability while mixing. The simulant and solution were sealed Burst Pouches® along with 2 other sealed bags to prevent material from leaking. Crew member F-14 conducted testing on the ISS by introducing the solution to the simulant in the Burst Pouch®, mixing the sample with a spatula, and then clamping the specimen in the fresh state to prevent flow inside the Burst Pouch®. These specimens were then put in a thermos heated to 80C via sealed drinking water bags to cure for 24 hours with a temperature logger. The cured specimens remained in microgravity for at least 28 days and were returned from the ISS in February 2025. The specimens were then brought to the NASA Marshall Space Flight Center (MSFC) to analyze. Material characterization consisted of conducting Micro-CT tests of entire samples in their sealed apparatus to a resolution of 25µm. 2D image slices were saved in each orthogonal direction of each specimen at a 0.03 mm step size from the 3D model to conduct analytical porosity calculations. Representative samples from each specimen were sampled to perform helium gas pycnometery and were then mounted in resin for SEM imaging, EDS, and nanoindentation. Porosity was analyzed analytically using micromechanics modelling with the assistance of the NASA Multiscale Analysis Tool (NASMAT), as well as the NASA Advanced Supercomputing (NAS) servers (V. Saseendran & N. Yamamoto, 2024). Density was measured using helium gas pycnometery and was then compared to the theoretical density for experimental porosity calculation. Due to the samples’ non-uniform shape being cured in a pouch, traditional compression and tensile strength testing could not be performed. Nanoindentation was conducted at Clarkson University to determine the microhardness and reduced modulus of elasticity. Results from flight samples can be compared to ground samples currently in DLR’s possession to determine the effect on microstructure from being mixed and cured in microgravity. This study gives further insight and understanding of geopolymer lunar concrete and its viability as a lunar construction material with ISRU.

Adam Johnson↗
NASA NTRSDate not supplied

Strong Thermoset Regolith UV-Curable Composite Technology (STRUCT) Overview

Future lunar surface missions require construction materials that can be manufactured in situ using lo-cal resources while operating under extreme environmental conditions. Many Lunar material demands can be solved solely with regolith by compacting or sintering. And yet past Lunar missions rely on polymeric materials, and sustained Lunar missions must reduce Earth-supplied polymers dependence. Dual-cure (Ultraviolet (UV) and thermal) polymer-regolith composites offer a promising pathway by leveraging solar UV radiation, moderate thermal in-put, and regolith. Mission mass limits, power availability and energy constraints on the lunar surface further motivate low-energy processing and curing strategies for surface construction materials. The Strong Thermoset Regolith UV-Curable Composite Technology (STRUCT) project has successfully synthesized and demonstrated dual-cure photopolymer resins derivable from in-situ resources [3]. Morphological, thermal, and mechanical characterization show that the newly formulated UV curable resin systems integrates well with lunar regolith simulants. Processing and chemistry changes, and computational analysis advanced the composite design. X-ray CT scanned and computational analysis demonstrate that resin, regolith and additives are well incorporated. The large fraction of regolith, 95% by mass, large char yield (82% mass), low thermal conductivity (0.26 W/m/K), confirm this material as a promising high-performance thermal and structural material.

thermal conductivity↗
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

(abstract) Unidirectional Carbon/Carbon for Ion Engine Optics

Conventional ion engine optical grids are made from hydroformed molybdenum. Carbon/carbon has been utilized in place of molybdenum because of its lower sputter yield, which contributes a greatly increased engine life, and for its low cte, which allows more efficient engine operation. The requirements for this material are that it must have high stiffness, very tight dimensional tolerances, and can be optimized for an hexagonal hole pattern with a very high open area friction. The carbon/carbon for this application was fabricated from unidirectional tape prepreg, using pitch fiber, and was processed to a very high temperature. The use of unidirectional tape allowed for a sufficient number of plies to be used to generate a balanced three directional layup within the thickness constraints of the material, as well as providing strength and stiffness over that normally seen with fabric based carbon/carbons.

ion engine carbon/carbon unidirectional tape prepr↗
NASA NTRSDate not supplied

Multi-Scale Thermo-Mechanical Modeling of Porous 3D Woven TPS Materials

This work summarizes the process to compute and analyze the thermal conductivity and mechanical properties of 3D woven TPS materials such as 3MDCP (3D Mid-Density Carbon-Phenolic). The PuMA [1,2] software, developed at NASA Ames, was used to characterize different 3MDCP samples from their constituents' data, averaging their thermal conductivity and elastic properties in the three main directions to obtain their effective orthotropic thermo-mechanical properties. This was performed in multiple steps: firstly, TPS samples were digitally reconstructed using micro computed tomography (µCT) and their constituents were segmented; then, the porous matrix phase was analyzed at the micro-scale and these results were used, along with the fibers’ constituents information, to model the tows at the meso-scale; finally, results from the constituents were homogenized and used to model the thermo-mechanical behavior of the unit cell at the macro-scale. Additionally, to gain a better understanding of the tows’ morphology and distribution of the carbon-phenolic blended fibers, microscopy images of the tows’ cross-section were segmented using deep learning techniques and analyzed with PuMA. This workflow can be applied to any TPS material to computationally obtain its thermo-mechanical properties, enabling more informed TPS design and manufacturing choices.

Multi-Scale↗
NASA NTRSDate not supplied

Multi-Scale Thermo-Mechanical Modeling of Porous 3D Woven TPS Materials

This work summarizes the process to compute and analyze the thermal conductivity and mechanical properties of 3D woven TPS materials such as 3MDCP (3D Mid-Density Carbon-Phenolic). The PuMA software, developed at NASA Ames, was used to characterize different 3MDCP samples from their constituents' data, averaging their thermal conductivity and elastic properties in the three main directions to obtain their effective orthotropic thermo-mechanical properties. This was performed in multiple steps: firstly, TPS samples were digitally reconstructed using micro computed tomography (µCT) and their constituents were segmented; then, the porous matrix phase was analyzed at the micro-scale and these results were used, along with the fibers’ constituents information, to model the tows at the meso-scale; finally, results from the constituents were homogenized and used to model the thermo-mechanical behavior of the unit cell at the macro-scale. Additionally, to gain a better understanding of the tows’ morphology and distribution of the carbon-phenolic blended fibers, microscopy images of the tows’ cross-section were segmented using deep learning techniques and analyzed with PuMA. This workflow can be applied to any TPS material to computationally obtain its thermo-mechanical properties, enabling more informed TPS design and manufacturing choices.

Multi-Scale↗
NASA NTRS2024

Material Inspectability Assessment Related to Lunar Construction Technology Development

For the building of lunar structures on the Moon using lunar regolith-based construction materials, ensuring their structural integrity and employing methods optimal for such tasks is crucial. In this technical memorandum (TM) the detectability of simulated void defects in a cementitious-based lunar construction material is compared between different nondestructive evaluation (NDE) methods, especially methods which have potential to be developed into space qualified instruments. Primarily, simulated voids, introduced during fabrication as foam spheres, were used for this evaluation. Furthermore, smaller, unintended void defects were used to assess the detectability. The results highlights trade-offs between the NDE methods in terms of detection limit, correct size indication, penetration depth, and potential for reduction in size, weight, and power (SWaP).

Nondestructive Evaluation↗