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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 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Development of novel techniques for non-invasive air leakage and moisture detection in building envelopes

Unwanted air leakage and moisture in building envelopes can cause high energy consumption, detrimental indoor air quality, poor occupant comfort, and reduction in building material durability. High moisture can cause rot and mold, leading to costly and time-consuming repairs that add to the carbon burden of the building envelope. Novel detection techniques for locating and measuring air leakage flow and areas of high moisture in building envelopes will be presented. The techniques are easy, fast, and non-destructive which can enable quick building envelope assessment, foster retrofits, and lead to energy savings and carbon emission reduction.

Boudreaux, Philip [ORNL] (ORCID:0000000229564665)↗
NASA NTRS1994

Using spacecraft trace contaminant control systems to cure sick building syndrome

Many residential and commercial buildings with centralized, recirculating, heating ventilation and air conditioning systems suffer from 'Sick Building Syndrome.' Ventilation rates are reduced to save energy costs, synthetic building materials off-gas contaminants, and unsafe levels of volatile organic compounds (VOC's) accumulate. These unsafe levels of contaminants can cause irritation of eyes and throat, fatigue and dizziness to building occupants. Increased ventilation, the primary method of treating Sick Building Syndrome is expensive (due to increased energy costs) and recently, the effectiveness of increased ventilation has been questioned. On spacecraft venting is not allowed, so the primary methods of air quality control are; source control, active filtering, and destruction of VOC's. Four non-venting contaminant removal technologies; strict material selection to provide source control, ambient temperature catalytic oxidation, photocatalytic oxidation, and uptake by higher plants, may have potential application for indoor air quality control.

Graf, John C.↗
NASA NTRSDate not supplied

Computationally Guided Development of Components for High Energy Density Solid-State Lithium-Sulfur Batteries

All electric vertical take-off and landing vehicles (eVTOL) for urban air mobility (UAM) concepts face numerous challenging technical barriers before their introduction into the consumer marketplace. The most challenging of these technical barriers to overcome is developing an energy storage system capable of meeting the rigorous aerospace safety and performance criteria1. The performance metrics for eVTOL craft, such as specific energy, specific power, and safety, exceed those of electric automobiles by a factor of two to four. Current state-of-the-art (SOA) lithium-ion batteries are incapable of meeting the key performance criteria of energy and safety for eVTOL. Therefore, next generation advanced chemistries and designs must be developed to meet required performance metrics for electric aviation2. Beyond lithium-ion chemistries, such as lithium-sulfur, show promise in their high energy, while limitations exist in their power and cyclability due to low electrical conductivity and high intermediate solubility in organic liquid electrolytes. Several strategies to overcome the low electrical conductivity involve the use of selenium as a dopant in the active sulfur material, along with the incorporation of 2-dimensional electron-conducting holey-graphene to improve the composite cathodes electronic conductivity. Furthermore, combining this chemistry with a solid-electrolyte avoids the components’ dissolution issues3. However, the development of composite solid-state cathodes is non-trivial as several components must be intimately mixed so that the active component has sufficient access to both electrons and lithium ions to undergo full electrochemical conversion. Mathematical modeling of battery components can assist experimental design through a robust and rigorous combination of computational modeling techniques covering multiple length scales. The objective is to leverage modern computational materials methods combined with battery multiphysics tools to develop radically advanced compatible cathode and electrolyte materials, build and test solid state lithium-sulfur cells and packs. A NASA-based cross-organizational team of high-powered experts combined integrated computational predictive modeling, fundamental chemistry analysis, advanced material science, and battery cell development to tackle this very challenging, multidisciplinary problem. This presentation will show a multiscale computational modeling approach that has produced a novel particle dynamics method called Solid Electrolyte Sphere Approximation Model (SESAM). SESAM modeling targets the 1-10 µm scale structures and provides electromechanical and grain interactions for predictive design guidelines for the manufacturing of solid-state components. Parameters such as particle size and volume fraction of the constituent materials were modeled and experimentally fabricated to optimize electrochemical performance through improved microstructure design. Experimental feedback was provided through ionic and electronic conductivity assessment and structural analysis of developed materials and cell components.

battery↗
NASA NTRS1991

Mining the air - Resources of other worlds may reduce mission costs

It is proposed that the mining of resources on another planet to support operations there and also to provide a means for the return trip to earth provides a less expensive way to send humans beyond low earth orbit to live on the moon and to explore Mars. Since a large fraction of any chemical propellant combination is the oxidizer that burns with the fuel to generate the rocket jet, and for life support, the generation of oxygen from any of its atmospheric or mineral compounds is a valuable capability. Such materials include the lunar minerals ilmenite and anorthite, Martian permafrost, water ice at the Martian poles, and atmospheric carbon dioxide on Mars. The possibilities of developing such technologies are discussed and the prospects of developing building materials for such facilities from local resources are considered. The role of the Space Engineering Research Center at the University of Arizona in exploring the use of local planetary resources is noted.

Ramohalli, Kumar↗
NASA NTRS1992

Shock-treated Lunar Soil Simulant: Preliminary Assessment as a Construction Material

In an effort to examine the feasibility of applying dynamic compaction techniques to fabricate construction materials from lunar regolith, preliminary explosive shock-loading experiments on lunar soil simulants were carried out. Analysis of our shock-treated samples suggests that binding additives, such as metallic aluminum powder, may provide the necessary characteristics to fabricate a strong and durable building material (lunar adobe) that takes advantage of a cheap base material available in abundance: lunar regolith.

Boslough, Mark B.↗
NASA NTRSDate not supplied

Enabling Evaluation of In-Situ Regolith-Based Construction Materials with Modified Methods for Testing Compressive Strength of Non-Cement Mortar Specimens Using Simulants & Analog Site Soils

Objectives for Phase II of NASA’s Artemis Program include establishment of lunar surface infrastructure to support a sustainable, long-term human presence on the Moon. Terrestrially, awareness of climate impacts from cement and concrete production has led to renewed interest in traditional building materials using earthen and pozzolanic binders with locally sourced aggregates [1, 2, 3]. In remote, austere,and resource-constrained environments, use of site-sourced materials is often an economic necessity in addition to being valuable for local autonomy and self-sufficiency. This study evaluates modifications to ASTM cement mortar testing methods, incorporating details from European standards for earthen plasters and lime-based mortars. Development of consistent, simplified methods for evaluating in-situ materials will be essential not only for meeting future climate goals and sustainable construction needs, but also for conducting autonomous robotic manipulation and evaluation of regolith construction materials.

ISRU↗
DOE OSTI2024

Characterization of Carbon Foam Products Made from Coal at Atmospheric Pressure

Carbon foam products are currently manufactured on a commercial scale utilizing a high-pressure autoclave in batch mode. In an effort to increase manufacturing speed and reduce cost, carbon foam products (both panels and aggregates) were produced at atmospheric pressure in a continuous belt kiln. Here, the microstructure, properties, and performance of these materials were characterized and assessed in various applications. Lightweight aggregate was explored for use as a proppant, as well as it use in concrete and asphalt. The thermal conductivity, water permeability, and fire resistance of panels were evaluated, and its performance with respect to screw pullout was compared against conventional building materials. Some interesting performance aspects and potential for future work was revealed. This work was supported by a cooperative agreement with the Department of Energy – National Energy Technology Laboratory (DE-FOA-0002185, Area of Interest 4: Coal-Derived Carbon Foam Produced via a Continuous Process, award number DE-FE-0031992).

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2026

Promotion of CaCO 3 Nucleation by Carboxyl- and Amine-Terminated Peptoid Nanotubes

The use of surfaces to promote heterogeneous nucleation of CaCO 3 has been extensively studied to better understand natural processes of biomineralization, to develop bioinspired approaches for synthesizing composite materials with diverse functionalities, and as a route toward accelerating CO 2 mineralization. Peptoids have emerged as a material of particular interest, because they offer tunable side chain chemistry while maintaining a constant long-range self-assembled architecture. Here, in this work, we investigate the ability of films of self-assembled -NH 2 and −COOH terminated peptoid nanotubes to promote the nucleation of CaCO 3 . Using a combination of atomic force, scanning electron, and optical microscopy, we find that interwoven films of nanotubes formed from peptoids with -NH 2 side chains promote the preferential formation of vaterite with the (001) plane parallel to the film and exhibit a lower interfacial energy than that reported for inorganic surfaces. In contrast, the film of −COOH-functionalized peptoid nanotubes is a much stronger promoter, giving a particle density 5 orders of magnitude larger than for the -NH 2 terminated peptoid nanotubes and enabling complete coverage of individual peptoid tubes with CaCO 3 nanoparticles that results in a composite material with a 50-fold increase in Young’s modulus. Thus, interwoven films of peptoid nanotubes provide a useful platform for investigating the impact of specific chemical groups on nucleation and offer potential application to accelerated mineralization of CO 2 for removal from the environment or modulation of mineralogy and properties of carbonate-based building materials.

carbon nanotubes↗
DOE OSTI2026

Measuring changes in environmental radiological background from construction of an advanced nuclear reactor testing facility

We present a method to survey and track changes in the environmental radiological background during the construction and operation of advanced nuclear reactor facilities. We discuss the results of two surveys of the environmental gamma-radiation background at NEXT Lab, an advanced nuclear reactor research facility on the campus of Abilene Christian University, prior to the introduction of radioactive material. In both surveys, the observed radiation dosage rates are low, with the highest rates at 15% of the average total radiation dosage rate for the United States. We observe ≈20% changes in the radiological background of the property in locations where the environment was changed by construction and ≈20% variations within the facilities correlated with variations in building materials.

Environment↗
DOE OSTI2025

Toward High-Voltage Cathodes for Zinc-Ion Batteries: Discovery Pipeline and Material Design Rules

Efficient energy storage systems are crucial to address the intermittency of renewable energy sources. As multivalent batteries, Zn-ion batteries (ZIBs), while inherently low voltage, offer a promising low-cost alternative to Li-ion batteries due to the viable use of zinc as the anode. However, to maximize the potential impact of ZIBs, rechargeable cathodes with improved Zn diffusion are needed. To better understand the chemical and structural factors influencing Zn-ion mobility within battery electrode materials, we employ a high-throughput computational screening approach to systematically evaluate candidate intercalation hosts for ZIB cathodes, expanding the chemical search space on empty intercalation hosts that do not contain Zn. We leverage a high-throughput screening funnel to identify promising cathodes in ZIBs, integrating screening criteria with density functional theory (DFT)-based calculations of Zn2+ intercalation and diffusion inside the host materials. Using these data, we identify the design principles that favor Zn-ion mobility in candidate cathode materials. Building on previous work on divalent-ion cathodes, this study broadens the chemical space for next-generation multivalent energy storage systems.

electrodes↗
NASA NTRS2024

Automation of the ICME Workflow Incorporating Material Digital Twins at Different Length Scales Within a Robust Information Management System

Recent successes in Integrated Computational Materials Engineering (ICME) have demonstrated the potential in designing ‘fit-for-purpose’ materials for a given application in a cost and time efficient manner. However, the material design process must contain a level of judicious automation in the material decision process; that is implementing some optimization algorithms to truly enable the benefits of ICME, particularly when considering materials at multiple length and time scales. Furthermore, the ability to effectively store developed material models, experimental data used for validation, and link models at multiple length and time scales must be implemented to ensure traceability across the material design process, such that the data gathered can be leveraged towards efficient material design. To enable such an optimization scheme a robust framework must exist: (1) that can capture changes made at a given length scale, (2) automatically propagate changes upstream to the highest scale, and (3) evaluate the material’s performance at the structural level. In this work, a developed framework for tracking material changes, automatically running the necessary simulations to determine the properties at the next highest scale, and saving each iteration of the design process to maintain the application’s digital thread is presented for polymer matrix composites (PMCs). The Automated Information Management Across Organizations and Scales (AIMAOS) program offers users an interactive graphical user interface (GUI) for defining constituent materials, building lamina and laminates, and applying effective laminate properties to finite element and composite optimization third party software. At each length scale, the necessary input files are automatically written, and subsequent analysis tools are called to solve for effective properties at the next scale, which are then read by the AIMAOS tool and displayed to the user. As changes are made to the material at lower length scales, information is automatically propagated upstream to higher length scales, and changes made are automatically tracked and versioned to maintain traceability during the design process. The AIMAOS tools serves as the first step in enabling optimized design of composites from the nano to the macroscale for a given application.

Brandon L Hearley↗
NASA NTRS2007

Sintering of Lunar and Simulant Glass

Most oxygen-extraction techniques are temperature-dependent, with higher temperatures resulting in higher oxygen yield. An example is hydrogen reduction, in which the optimum process temperature is 1050 C. However, glass-rich lunar soil begins to show the effects of sintering at temperatures of 900 C or lower. Sintering welds particles together due to viscous relaxation of the glass in the sample. One approach to avoid problems related to sintering, such as difficulty in removing waste material from the reactor, is to keep the soil in motion. One of several methods being studied to accomplish this is fluidized-bed processing techniques, in which the grains are kept in motion by the action of flowing reductant gas. The spent material can be removed from the chamber while still fluidized, or the fluidizing motion can continue until the material has cooled below approx. 500 C. Until end-to-end prototypes are built that can remove the heated soil, the most practical option is to keep the bed fluidized while cooling the waste material. As ISRU technology advances, another option will become valuable, which is to intentionally sinter the material to a great enough extent that it becomes a brick. The free iron in lunar soil is magnetic, and ferromagnetic bricks can be manipulated by robotic systems using electromagnetic end effectors. Finally, if an electromagnetic field is applied to the soil while the brick is being formed, the brick itself will become a magnet. This property can be used to create self-aligning bricks or other building materials that do not require fasteners. Although sintering creates a challenge for early lunar surface systems, knowledge gained during prototype development will be valuable for the advanced lunar outpost.

Cooper, Bonnie L.↗
NASA NTRS2015

Computational Process Modeling for Additive Manufacturing (OSU)

Powder-Bed Additive Manufacturing (AM) through Direct Metal Laser Sintering (DMLS) or Selective Laser Melting (SLM) is being used by NASA and the Aerospace industry to "print" parts that traditionally are very complex, high cost, or long schedule lead items. The process spreads a thin layer of metal powder over a build platform, then melts the powder in a series of welds in a desired shape. The next layer of powder is applied, and the process is repeated until layer-by-layer, a very complex part can be built. This reduces cost and schedule by eliminating very complex tooling and processes traditionally used in aerospace component manufacturing. To use the process to print end-use items, NASA seeks to understand SLM material well enough to develop a method of qualifying parts for space flight operation. Traditionally, a new material process takes many years and high investment to generate statistical databases and experiential knowledge, but computational modeling can truncate the schedule and cost -many experiments can be run quickly in a model, which would take years and a high material cost to run empirically. This project seeks to optimize material build parameters with reduced time and cost through modeling.

Bagg, Stacey↗
NASA NTRS1991

Indigenous lunar construction materials

The utilization of local resources for the construction and operation of a lunar base can significantly reduce the cost of transporting materials and supplies from Earth. The feasibility of processing lunar regolith to form construction materials and structural components is investigated. A preliminary review of potential processing methods such as sintering, hot-pressing, liquification, and cast basalt techniques, was completed. The processing method proposed is a variation on the cast basalt technique. It involves liquification of the regolith at 1200-1300 C, casting the liquid into a form, and controlled cooling. While the process temperature is higher than that for sintering or hot-pressing (1000-1100 C), this method is expected to yield a true engineering material with low variability in properties, high strength, and the potential to form large structural components. A scenario for this processing method was integrated with a design for a representative lunar base structure and potential construction techniques. The lunar shelter design is for a modular, segmented, pressurized, hemispherical dome which could serve as habitation and laboratory space. Based on this design, estimates of requirements for power, processing equipment, and construction equipment were made. This proposed combination of material processing method, structural design, and support requirements will help to establish the feasibility of lunar base construction using indigenous materials. Future work will refine the steps of the processing method. Specific areas where more information is needed are: furnace characteristics in vacuum; heat transfer during liquification; viscosity, pouring and forming behavior of molten regolith; design of high temperature forms; heat transfer during cooling; recrystallization of basalt; and refinement of estimates of elastic moduli, compressive and tensile strength, thermal expansion coefficient, thermal conductivity, and heat capacity. The preliminary design of the lunar shelter showed us that joining is a critical technology needed for building a structure from large segments. The problem of joining is important to the design of any structure that is not completely prefabricated. It is especially important when the structure is subjected to tensile loading by an internal pressure. For a lunar shelter constructed from large segments the joints between these large segments must be strong, and they must permit automated construction. With a cast basalt building material which is brittle, there is the additional problem of connecting the joint with the material and avoiding stress concentration that would cause failure. Thus, a well-defined project which we intend to pursue during this coming year is the design of joints for cast basalt structural elements.

Rogers, Wayne P.↗
NASA NTRS2018

Integrated Computational-Experimental Development of Lithium-Air Batteries for Electric Aircraft

The primary obstacle to enable NASA's vision of Green Aviation is the extraordinary energy storage requirements for electric aircraft. Significant advances in high energy, rechargeable, safe batteries are required to enable electric aviation. Boeing's SUGAR and NASA studies have identified 400 Wh/kg as the threshold energy density for general aviation and 750 Wh/kg for commercial regional air service. State of the Art Lithium Ion Battery (LIB) technology currently has a density of 200 Wh/kg and is expected to plateau at 300 Wh/kg due to fundamental chemistry limitations making it unsuitable for future electric aircraft. Additional demanding requirements include high power, rechargeability, and high safety. Such battery technology does not currently exist. The recent considerable activity in battery research (DOE, Tesla Gigafactory, etc) overwhelmingly has been geared towards reducing cost and improving safety of LIB technology in order to promote the adoption of electric automobiles; and thus it is expected to have little impact on electric aviation development. New battery materials will be needed for the "Beyond Li Ion" (BLI) technologies required for high energy, safe electric aviation. Li-Air batteries have the highest known theoretical energy density (3400 Wh/kg) and therefore and if realized promises to transform the global transportation system. These high energy batteries have the potential to meet the energy storage challenges of current and future NASA aeronautics and space missions in addition to many terrestrial transportation applications as well. However, this technology requires significant components development and integration, as it is currently unable to achieve aircraft requirements. The objective of this project is to leverage modern computational materials methods combined with battery multiphysics tools to develop radically advanced compatible cathode and electrolyte materials, build several Li-Air cells, and flight-demonstrate the corresponding Li-Air battery packs. A significant problem for current Lithium-Air batteries is large scale decomposition of the battery electrolyte during operation leading to battery failure after a handful of charge/discharge cycles. Therefore, development of large scale, ultra-high energy, rechargeable, and safe Lithium-Air batteries require highly stable electrolytes that are resistant to decomposition under operating conditions. A NASA-based cross-organizational "dream team" of high-powered experts combined integrated supercomputer modeling, fundamental chemistry analysis, advanced material science, and battery cell development to tackle this very challenging, multidisciplinary problem. The ultimate goal for the team is to develop an integrated experimental/computational infrastructure to produce a reliable predictive capability for the selection of optimal components, their fabrication parameters, and "design rules" of novel cell components for advanced ultra-high energy batteries that can meet energy storage challenges of NASA missions and many terrestrial transportation applications.

Li-air battery↗
DOE OSTI2024

Manufacturing of Continuous Core–Shell Hydrated Salt Fibers for Room Temperature Thermal Energy Storage

The encapsulation of salt hydrate phase change materials (PCMs) in uniform microscale bodies has yet been reported in research due in part to the delicate relationship between thermal performance and water-to-salt ratios which are easily altered during manufacturing. Herein, core–shell composite fibers comprised of a salt hydrate PCM core and a poly(acrylonitrile) (PAN) shell are wet spun in a continuous process using a syringe pump and coaxial die. The PCM phase comprises calcium chloride hexahydrate (CaCl 2 ·6H 2 O) with strontium chloride hexahydrate(SrCl 2 ·6H 2 O) (3 wt%) and fumed silica(SiO 2 ) (2 wt%) as additive, a composition that is prepared from homogenous melt at 40 °C. 15 wt% PAN in dimethylsulfoxide solvent is used to prepare the shell-forming polymer gel. PCM and polymer gel injection rates of 10–40 mL h –1 are used to spin coaxial fibers through a coagulation bath, yielding continuous microtubules with diameters in the range of 850–1500 μm. Cyclic testing shows that after 1000 cycles, melting enthalpies incurred only a 3.5% decline from 131.46 to 126.9 J g –1 . In conclusion, success here overcomes several coincidental drawbacks of PCM fiber performance and manufacturing and delivers the first example of scalable roll-to-roll PCM fiber produced by wet spinning for building material applications.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Towards an understanding of particle-scale flaws and microstructure evolution in cold spray via accumulation of single particle impacts

Cold spray coatings are the sum of countless individual bonding events between single particles impacting on top of one another at high velocities. Thus, the collective behavior of microparticles must be considered to elucidate the origins of coating flaws at the scale of the particles and larger, or the dynamic evolution of the overall coating microstructure. Laser-induced particle impact testing (LIPIT) has been extensively used to study single-particle impacts, and in this work is adapted to study the accumulation of numerous particles with knowledge of each individual particle's impact parameters (particle size, velocity). The method reproducibly deposits stacks of gold particles (>20 particles) with different characteristic spectra of impact velocity. The observation of impact-induced erosion lets us define a critical velocity for material-build-up that is higher than that for single-particle bonding. The quantitative single-particle data are analyzed in a correlative manner to the structure and flaws in the resulting stacks, providing some first statistical connections between, e.g., strain and recrystallization, or aberrant particle characteristics and defects. The results highlight opportunities for the study of many-particle phenomena in microparticle impact—from interaction of particles in cold spray to multi-step erosion processes—with a quantitative view of the behavior of single particles.

Erosion↗
DOE OSTI2025

Carbonation reaction of recycled concrete aggregates (RCA): CO 2 mass consumption under various treatment conditions

Concrete is a key building material around the world due to its excellent strength and durability. Recycling demolished concrete for new construction materials may play a significant role in sustainable development. Producing recycled concrete aggregates (RCA) from waste concrete is one approach for such an initiative. However, using RCA may pose challenges, such as reduced density, lower elastic modulus and strength, and increased water absorption. Recently, the carbonation of RCA has emerged as a method to address those concerns. This study explores the carbon sequestration capacity of RCA through carbonation, examining various parametric conditions, including initial CO 2 pressure, relative humidity, temperature, and pre-treatment approach. Both lab-scale and large-scale carbonation tests were conducted. Additionally, a cost analysis and CO 2 footprint assessment were performed. The findings showed that applying higher initial CO 2 pressures (e.g., 40–60 psi) and optimal relative humidity (~55 %) could significantly enhance the carbonation efficiency of RCA. Elevating temperature also led to accelerated CO 2 consumption, being more effective on the lab scale. The economic analysis presented potential cost benefits when substituting natural aggregates with CO 2 -treated RCA. All in all, these results suggest that the carbonation of RCA may provide significant environmental benefits through carbon sequestration, promoting sustainable construction practices.

36 MATERIALS SCIENCE↗