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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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At least 379 records · Page 21
All sourcesNASA NTRSDOE OSTI
NASA NTRS2015

[Redesign of the Spacesuit Long Life Battery and the Personal Life Support System Battery]

This fall I was working on two different projects that culminated into a redesign of the spacesuit LLB (long life battery). I also did some work on the PLSS (personal life support system) battery with EC. My first project was redlining the work instruction for completing DPAs (destructive physical analysis) on battery cells in the department. The purpose of this document is to create a standard process and ensure that the data in the same way no matter who carries out the analysis. I observed three DPAs, conducted one with help, and conducted two on my own all while taking notes on the procedure. These notes were used to write the final work instruction that will become is the department standard. My second project continued the work of the summer co-op before me. I was testing aluminum heat sinks for their ability to provide good thermal conduction and structural support during a thermal runaway event. The heat sinks were designed by the summer intern but there was not much time for testing before he left. We ran tests with a heater on the bottom of a trigger cell to try to drive thermal runaway and ensure that it will not propagate to adjacent cells. We also ran heat-to-vent tests in an oven to see if the assembly provided structural support and prevented sidewall rupture during thermal runaway. These tests were carried out at ESTA (energy systems test area) and are providing very promising results that safe, high performing (greater than 180 Wh/kg) designs are possible. My main project was a redesign of the LLB battery. Another summer intern did some testing and concluded that there was no simple fix to mitigate thermal runaway propagation hazards in the current design. The only option was a clean sheet redesign of the battery. I was given a volume and ideal energy density and the rest of the design was up to me. First, I created new heat sink banks in Creo using the information gathered in the metal heat sink tests from the summer intern. After this, I made capture plates to hold the cells in place and I worked on nickel bussings for the electrical connections between the cells. Finally, I designed the test box enclosure that included sections for flame arresting materials. The battery brick design, which is the heart of the battery, promises to become the first for a manned spacecraft application to achieve greater than 180 Wh/kg. My work in redlining the DPA work instructions will also be used in selecting the cells for the battery. We had a few options of cells that would provide the necessary power output and needed to make a choice. We repeatedly charged and discharged cells for around a month until they went through 100 lifecycles. The plan is to compare the DPA results on fresh and cycled cells from each manufacturer to see if cycling introduces any differences. After the complete LLB design was approved, the parts were ordered and testing should begin the first week of December. Some of my side projects included working on the CAD data for the PLSS with EC and attending the NASA Aerospace Battery Workshop in Huntsville. I was also a member of the Tours and Lectures Committee for the USRA and Pathways interns. I coordinated Apollo Evening and was on the committee for touring KSC and seeing an Atlas 5 launch. I really enjoyed my time at JSC and I would like to continue working for NASA or another aerospace company in the future. I have worked other internships prior to this, but I think the heavy research and development focus is the best fit for me. I originally thought I would need to go to grad school to work in an environment like this, but I now see it is possible with a bachelor’s degree and hard work. I would like to go into the workforce and maybe continue my education with night classes.

Scharf, Stephanie↗
NASA NTRS1977

Transparent superstrate terrestrial solar cell module

The design, development, fabrication, and testing of the transparent solar cell module were examined. Cell performance and material process characteristics were determined by extensive tests and design modifications were made prior to preproduction fabrication. These tests included three cell submodules and two full size engineering modules. Along with hardware and test activity, engineering documentation was prepared and submitted.

Source record↗
NASA NTRSDate not supplied

An Approach to Shape Parameterization Using Laboratory Hypervelocity Impact Experiments

NASA’s Orbital Debris Program Office relies on laboratory-based impact tests to supplement the measurement data of on-orbit events that defines the orbital debris environment. These experiments provide information that is essential to interpreting the radar and optical measurements of orbital fragmentation events into useful metrics, such as characteristic size of the debris, and to providing a better understanding of the distributions of fragment populations in terms of their masses, material constituents, fragment densities, cross-sectional areas, area-to-mass ratios, shapes, etc. The Satellite Orbital Debris Characterization Impact Test (SOCIT) was a notable laboratory impact experiment conducted in 1992 using a surplus U.S. Navy Transit navigation satellite of the 1960s. The data from this ground-based experiment were combined with on-orbit measurements to develop the NASA Standard Satellite Breakup Model (SSBM). To account for advancements in satellite design and construction since, a new impact test series – DebriSat – was conducted in 2014. This test utilized a high-fidelity mock-up spacecraft that better represents the materials and construction techniques used to design and manufacture modern spacecraft. Together, these tests offer valuable data to model an orbital debris environment composed of legacy and modern spacecraft. This paper presents an overview of the two laboratory impact tests, comparing their fragment parameter distributions with each other and with relevant distributions from the NASA SSBM. The categorization and descriptions of fragment shapes are of significant interest for future work, yet there are marked differences in the definitions of shape categories between each dataset. The categorizations of constituent materials, and the measurement techniques employed to populate these two datasets, are also different. New rubrics simplify and equate the categorizations between datasets to aid comparative analyses and to facilitate the potential use of both datasets in tandem with future environmental debris models. A preferred approach to classifying shape across disparate datasets uses the characteristic-length dimensions, and a simplified shape classification based on physical, solid-body dimensions, to mathematically construct an encapsulating right-circular cylinder that represents the fragment. The ratio of cylinder length-to-diameter (L:D) then provides a single continuum value for shape that is strongly correlated with its designated shape and size. This metric can then be used to further assess the distribution of shape with populations of other fragment characteristics within these datasets. The shape parameterization using the L:D ratios of right-circular cylinders is discussed.

John H. Seago↗
NASA NTRSDate not supplied

An Approach to Shape Parameterization Using Laboratory Hypervelocity Impact Experiments

NASA’s Orbital Debris Program Office relies on laboratory-based impact tests to supplement the measurement data of on-orbit events that defines the orbital debris environment. These experiments provide information that is essential to interpreting the radar and optical measurements of orbital fragmentation events into useful metrics, such as characteristic size of the debris, and to providing a better understanding of the distributions of fragment populations in terms of their masses, material constituents, fragment densities, cross-sectional areas, area-to-mass ratios, shapes, etc. The Satellite Orbital Debris Characterization Impact Test (SOCIT) was a notable laboratory impact experiment conducted in 1992 using a surplus U.S. Navy Transit navigation satellite of the 1960s. The data from this ground-based experiment were combined with on-orbit measurements to develop the NASA Standard Satellite Breakup Model (SSBM). To account for advancements in satellite design and construction since, a new impact test series – DebriSat – was conducted in 2014. This test utilized a high-fidelity mock-up spacecraft that better represents the materials and construction techniques used to design and manufacture modern spacecraft. Together, these tests offer valuable data to model an orbital debris environment composed of legacy and modern spacecraft. This paper presents an overview of the two laboratory impact tests, comparing their fragment parameter distributions with each other and with relevant distributions from the NASA SSBM. The categorization and descriptions of fragment shapes are of significant interest for future work, yet there are marked differences in the definitions of shape categories between each dataset. The categorizations of constituent materials, and the measurement techniques employed to populate these two datasets, are also different. New rubrics simplify and equate the categorizations between datasets to aid comparative analyses and to facilitate the potential use of both datasets in tandem with future environmental debris models. A preferred approach to classifying shape across disparate datasets uses the characteristic-length dimensions, and a simplified shape classification based on physical, solid-body dimensions, to mathematically construct an encapsulating right-circular cylinder that represents the fragment. The ratio of cylinder length-to-diameter (L:D) then provides a single continuum value for shape that is strongly correlated with its designated shape and size. This metric can then be used to further assess the distribution of shape with populations of other fragment characteristics within these datasets. The shape parameterization using the L:D ratios of right-circular cylinders is discussed.

John H Seago↗
NASA NTRS2001

A New Method for Evaluating Elastomeric Materials for Use in High Pressure Oxygen

The seal configuration tester (SCT) developed at the Stennis Space Center (SSC) was designed to replicate the intended application of different seat and seal materials in a high pressure oxygen system and assess the wearibility of those materials. Statistical models were used to test the reliability of the SCT in its intended application, and the tests showed very consistent measurements over time, indicating that the device was working as intended. Other statistical designs were used to test different O-ring materials in a high-pressure oxygen system. Those tests indicated that the SCT could be used to rank the performance of O-ring materials in certain environments. The results indicated that some cheaper materials performed as well as, if not better than, other more expensive materials. Different lubrications were integrated in the testing as well and had a significant impact on the performance of the materials. Testing of seat materials is the next stage of this project. An augmentation grant (JAG) was obtained to further this experimental testing at the Stennis Space Center. This part of the project is ongoing at this time and therefore there are no significant accomplishments with respect to seat materials as of yet.

Jordan, Scott M.↗
NASA NTRS1975

Permanent and separable aerospace tubing/ fitting evaluation program, volume 1

The tube fitting evaluation program was conducted to develop a standard overall test program including methods, procedures, and equipment as well as recommended test sequences for qualifying fitting/tubing assemblies. The program consisted of testing the MS flareless (separable) fitting and utilizing the results as baseline data from which all other fittings will be evaluated. Five separable designs and five permanent designs were tested in three sizes with two types of tubing materials. The basic design requirements were 4,000 psi operating pressure within the temperature range of minus 65 F to plus 450 F while also being compatible with 21-6-9 and titanium 3Al-2.5V tubing alloys.

Ursell, C. R.↗
NASA NTRS1993

Model of spacecraft atomic oxygen and solar exposure microenvironments

Computer models of environmental conditions in Earth orbit are needed for the following reasons: (1) derivation of material performance parameters from orbital test data, (2) evaluation of spacecraft hardware designs, (3) prediction of material service life, and (4) scheduling spacecraft maintenance. To meet these needs, Boeing has developed programs for modeling atomic oxygen (AO) and solar radiation exposures. The model allows determination of AO and solar ultraviolet (UV) radiation exposures for spacecraft surfaces (1) in arbitrary orientations with respect to the direction of spacecraft motion, (2) overall ranges of solar conditions, and (3) for any mission duration. The models have been successfully applied to prediction of experiment environments on the Long Duration Exposure Facility (LDEF) and for analysis of selected hardware designs for deployment on other spacecraft. The work on these models has been reported at previous LDEF conferences. Since publication of these reports, a revision has been made to the AO calculation for LDEF, and further work has been done on the microenvironments model for solar exposure.

Bourassa, R. J.↗
NASA NTRS2008

Selectable-Tip Corrosion-Testing Electrochemical Cell

The figure depicts aspects of an electrochemical cell for pitting- corrosion tests of material specimens. The cell is designed to generate a region of corrosion having a pit diameter determined by the diameter of a selectable tip. The average depth of corrosion is controlled by controlling the total electric charge passing through the cell in a test. The cell is also designed to produce minimal artifacts associated with crevice corrosion. There are three selectable tips, having diameters of 0.1 in. (0.254 cm), 0.3 in. (0.762 cm), and 0.6 in. (1.524 cm), respectively.

Lomness, Janice↗
NASA NTRS2009

Applicability of Aerospace Materials Ground Flammability Test Data to Spacecraft Environments Theory and Applied Technologies

This slide presentation reviews the use of ground test data in reference to flammability to spacecraft environments. It reviews the current approach to spacecraft fire safety, the challenges to fire safety that the Constellation program poses, the current trends in the evaluation of the Constellation materials flammability, and the correlation of test data from ground flammability tests with the spacecraft environment. Included is a proposal for testing and the design of experiments to test the flammability of materials under similar spacecraft conditions.

Hirsch, David↗
NASA NTRSDate not supplied

Simulation of Dynamic Crushing Behavior of Simulated Carbon/Epoxy Stanchions Using MAT58 and MAT213 in LS-DYNA

Carbon fiber-reinforced polymer (CFRP) composites have shown promise as a material for structures designed to absorb energy in crush-style impact loading. In complementing the lightweight and tailorable characteristics of CFRP structures, the benefits of impact energy absorption are particularly interesting in aerospace vehicles that require excellent crashworthiness performance. However, simulating the behavior of CFRP structures in dynamic, crushing-style impact loading is challenging because of the many damage and failure modes that are essential to capture in the model. For the present investigation, CFRP stanchions were tested using a crash sled experimental test rig. The stanchions were designed by the Composite Materials Handbook-17 (CMH-17) Crashworthiness Working Group for the purpose of comparing experimental crash sled tests to corresponding simulations of the tests. The stanchions are C-channel shaped and represent a geometry common in the interior of aerospace vehicle structures. Explicit simulations in LSDYNA were performed using a well-established composite material model (MAT58) and a next-generation material model (MAT213). Fully integrated shell elements were utilized instead of 3D solid elements to limit computation time. In all models, each of the sixteen plies were represented with individual layers of shell elements with tiebreak contact between each adjacent ply pair to simulate interlaminar fracture. Simulating the crushing of the stanchions occurred in two phases. First, the material models were calibrated using flat specimens that were manufactured with the same layup as the stanchions. While the original goal was calibration of material-related properties, meshdependent behavior was observed in simulations with either material model, and an unstructured mesh was selected to remediate undesirable mesh-dependent failure modes. Additionally, for both the MAT58 and MAT213 models, it was found that either the crush force or the failure mode could be modeled accurately, but no set of parameters could be identified to attain both results in the same model. Once satisfactory calibration was achieved, the same material parameters were applied to the stanchion crush simulations. The stanchion simulations showed that MAT213 more accurately predicted the experimentally determined crush force, and both material models predicted key aspects of the experimentally observed failure modes.

Composite Materials↗
DOE OSTI2024

Surveillance Test Articles Development

Overview of previous work at ANL: • Initial designs tested with A617 driver • 3 families of specimens: - Large: demonstrate failure during test - Small: demonstrate realistic-sized samples - Reference: to validate the strain-gauge thermal strain correction • Thermal cycling between 500 and 650, over a period of about 200 minutes • Demonstrated basic surveillance approach • Large specimens failed in gauge section • The bimetallic welds appeared intact at the end of testing (316H-A617) • Gradual decrease in strain range over time • Strain gauge reliability was an issue: at least one gauge failed • Failure mode (buckling) was not what we had expected

36 MATERIALS SCIENCE↗
NASA NTRS1978

Status of the NASA-Lewis Research Center spacecraft charging investigation

The technology necessary to control the absolute and differental charging of spacecraft surfaces is detailed for developing ground simulation facilities, characterizing the charging and discharging characteristics of spacecraft materials, deriving analytical modelling tools and issuing design guideline documents. Facilities were developed and testing of various materials was completed. Comparisons between experimental results, space results and predictions from models were made. Harness transient monitors were flown on satellites.

Stevens, N. J.↗
NASA NTRS2000

MC-1 Nozzle Testing Results

This document is the presentation graphics which reviews the test results of the MC-1 Nozzle. The MC-1 Nozzle was originally designed for a low cost engine for an expendable booster. It was modified for use in the X-34 propulsion plant. With this design the nozzle and chamber are one piece. The presentation reviews the design goals, the materials and fabrication. The tests and results are reviewed in considerable detail. Included are pictures of the nozzle, and diagrams of the nozzle geometry

Peters, Warren↗
NASA NTRS2026

Expanding Space with Inflatable Softgoods: Roadmap for In-Space Manufacturing of Resilient Space Structures

Overview of inflatable softgoods and their emerging role in enabling large, resilient space habitats and infrastructure. It highlights the advantages of inflatable systems, such as exceptional packing efficiency and scalable habitable volume, while also addressing challenges related to outfitting, complex material behavior, structural design, manufacturing precision, and testing limitations. Core architectural elements of crewed inflatable habitats are described, along with shell layer composition, structural interfaces, and examples of conceptual habitat configurations for transit, lunar, and surface applications. The presentation concludes by outlining key technology shortfalls, including structural health monitoring, ultra‑high‑strength materials, lifetime performance, and integration strategies, emphasizing the need for continued development to support future in‑space manufacturing and exploration missions.

Habitat↗
NASA NTRS1991

Experimental investigation of a solid rocket combustion simulator

The response of solid rocket motor materials to high-temperature corrosive gases is usually accomplished by testing the materials in a subscale solid rocket motor. While this imposes the proper thermal and chemical environment, a solid rocket motor does not provide practical features that would enhance systematic evaluations such as: the ability to throttle for margin testing, on/off capability, low test cost, and a low-hazards test article. Solid Rocket Combustion Simulators (SRCS) are being evaluated by NASA to test solid rocket nozzle materials and incorporate these essential practical features into the testing of rocket materials. The SRCS is designed to generate the thermochemical environment of a solid rocket. It uses hybrid rocket motor technology in which gaseous oxygen (Gox) is injected into a chamber containing a solid fuel grain. Specific chemicals are injected in the aft mixing chamber so that the gases entering the test section match the temperature and a non-dimensional erosion factor B' to insure similarity with a solid motor. Because the oxygen flow can be controlled, this approach allows margin testing, the ability to throttle, and an on/off capability. The fuel grains are inert which makes the test article very safe to handle. The objective of this work was to establish the baseline operating characteristics of a Labscale Solid Rocket Combustion Simulator (LSRCS). This included establishing the baseline burning rates of plexiglass fuels and the evaluation of a combustion instability for hydroxy-terminated polybutadyene (HTPB) propellants. The scope of the project included: (1) activation of MSFC Labscale Hybrid Combustion Simulator; (2) testing of plexiglass fuel at Gox ranges from 0.025 to 0.200 lb/s; (3) burning HTPB fuels at a Gox rate of 0.200 lb/s using four different mixing chamber configurations; and (4) evaluating the fuel regression and chamber pressure responses of each firing.

Frederick, Robert A., Jr.↗
DOE OSTI2025

ORNL Package Testing Program Overview

Radioactive materials are widespread in our everyday activities which are used in many different types of industries: Consumer products, Medicine, Industry, Energy, and Defense. In the United States there is about 3 million shipments of radioactive materials per year. With radioactive material being very widespread the number of new applications to ship these quantities increases daily. As such, ensuring the safe and secure transport of these materials is paramount, necessitating stringent packaging, transportation, and certification requirements. Shipments of radioactive materials have been made from Oak Ridge National Laboratory (ORNL) for the past 65 years. Since the 1940s ORNL has been at the forefront of the early development of regulations pertaining to the transport of radioactive shipments and associated regulatory testing. The early involvement resulted in ORNL being one of the leaders in the development of regulations and testing standards pertaining to the testing and design of packages. Today all package testing activities are conducted under the Package Testing Program (PTP) at ORNL at the Package Evaluation Facility (PEF). The PTP develops and evaluates testing solutions – ensuring that they are safe, efficient, and meet regulatory requirements ORNL PTP has extensive experience in the regulatory testing of radioactive material packages, supporting certification of Type A, Type, B, Type AF, and special form packages. The PEF serves as a one-stop-shop for design, testing, and certification of a wide variety of packages needed for shipment of radioactive materials. The facility provides the space, expertise, and equipment necessary to conduct rigorous performance testing under both normal and accident conditions or transport environments including free drop, dynamic crush, puncture, penetration, compression, vibration, water spray, water immersion, and thermal test. The PTP remains a key contributor to the safety and compliance of radioactive material transportation. This presentation will provide an overview of the program’s history, capabilities, and its ongoing role in advancing regulatory standards and transportation safety.

Martinez, Oscar [ORNL] (ORCID:0000000181814046)↗
NASA NTRS2014

Development and Experimental Evaluation of Passive Fuel Cell Thermal Control

To provide uniform cooling for a fuel cell stack, a cooling plate concept was evaluated. This concept utilized thin cooling plates to extract heat from the interior of a fuel cell stack and move this heat to a cooling manifold where it can be transferred to an external cooling fluid. The advantages of this cooling approach include a reduced number of ancillary components and the ability to directly utilize an external cooling fluid loop for cooling the fuel cell stack. A number of different types of cooling plates and manifolds were developed. The cooling plates consisted of two main types; a plate based on thermopyrolytic graphite (TPG) and a planar (or flat plate) heat pipe. The plates, along with solid metal control samples, were tested for both thermal and electrical conductivity. To transfer heat from the cooling plates to the cooling fluid, a number of manifold designs utilizing various materials were devised, constructed, and tested. A key aspect of the manifold was that it had to be electrically nonconductive so it would not short out the fuel cell stack during operation. Different manifold and cooling plate configurations were tested in a vacuum chamber to minimize convective heat losses. Cooling plates were placed in the grooves within the manifolds and heated with surface-mounted electric pad heaters. The plate temperature and its thermal distribution were recorded for all tested combinations of manifold cooling flow rates and heater power loads. This testing simulated the performance of the cooling plates and manifold within an operational fuel cell stack. Different types of control valves and control schemes were tested and evaluated based on their ability to maintain a constant temperature of the cooling plates. The control valves regulated the cooling fluid flow through the manifold, thereby controlling the heat flow to the cooling fluid. Through this work, a cooling plate and manifold system was developed that could maintain the cooling plates within a minimal temperature band with negligible thermal gradients over power profiles that would be experienced within an operating fuel cell stack.

Fuel Cells↗
DOE OSTI2023

ABF Industry Engagement Lab Call with Danimer Scientific

This Agile BioFoundry Directed Funding Opportunity project with Danimer Scientific focuses on the development of a strain and a corresponding bioprocess to convert bio-based feedstocks to mixed composition polyhydroxyalkanoates (PHAs). Danimer Scientific produces PHAs today at industrial scale in proprietary strains and for many applications where bio-based, biodegradable materials are advantaged. The project team consists of NREL to lead the strain engineering efforts, PNNL to conduct systems biology experiments that will inform further strain engineering, and Danimer to conduct bioprocess development and materials development. To date, we have on-boarded Danimer strains and demonstrated successful engineering thereof. We anticipate conducting systems biology studies in Spring 2023. Overall, the impact of this DFO project could be improved material properties accessed through the Design-Build-Test-Learn cycle for designer PHA production.

bio-based feedstocks↗