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Characterization Testing of a 20 Kelvin Cryocooler for Space Applications

Future NASA space exploration missions will require long-duration storage and liquefaction of cryogenic liquids, enabled by active cooling provided by cryocoolers. Recent gap analyses of Lunar and Mars transportation systems have identified 20 K-class cryocoolers as a critical enabling technology for chemical and nuclear thermal propulsion architectures using liquid hydrogen propellant. To address this technology gap, NASA has undergone the development of a high-efficiency, high-capacity 20 K cryocooler via an SBIR partnership with Creare. While the January 2025 testing demonstrated functionality and compliance with contractual requirements, the objective of the NASA-led characterization effort was to generate a dataset for supporting future mission designs across a broader operating envelope, including off-nominal conditions. The cryocooler demonstrated strong performance, achieving a peak coefficient of performance of 17.68% relative to Carnot efficiency and a maximum lift capacity of 24.4 W at 21 K. Overall, the results confirm that the 20 W 20 K cryocooler provides a flexible range of capabilities to enable zero boil-off storage of liquid hydrogen for future Lunar and Mars missions. The data collected provide a strong foundation for model validation and future system design efforts.

Cryocooler

Characterization Testing of a 20 Kelvin Cryocooler for Space Applications

Future NASA space exploration missions will require long-duration storage and liquefaction of cryogenic liquids, enabled by active cooling provided by cryocoolers. Recent gap analyses of Lunar and Mars transportation systems have identified 20 K-class cryocoolers as a critical enabling technology for chemical and nuclear thermal propulsion architectures using liquid hydrogen propellant. To address this technology gap, NASA has undergone the development of a high-efficiency, high-capacity 20 K cryocooler via an SBIR partnership with Creare. While the January 2025 testing demonstrated functionality and compliance with contractual requirements, the objective of the NASA-led characterization effort was to generate a dataset for supporting future mission designs across a broader operating envelope, including off-nominal conditions. The cryocooler demonstrated strong performance, achieving a peak coefficient of performance of 17.68% relative to Carnot efficiency and a maximum lift capacity of 24.4 W at 21 K. Overall, the results confirm that the 20 W 20 K cryocooler provides a flexible range of capabilities to enable zero boil-off storage of liquid hydrogen for future Lunar and Mars missions. The data collected provide a strong foundation for model validation and future system design efforts.

Zero boil-off

Battery Evaluation Profiles for X-57 and Future Urban Electric Aircraft

Battery energy density is one of the most critical design parameters for sizing all-electric aircraft, however it’s easily overestimated. Establishing the effective, usable energy density is confused by varying degrees of margin needed to account for structural and thermal management between different cell chemistry and pack designs. Therefore, a better methodology is needed to fairly compare emerging battery technologies for electric aircraft. Currently, there is a loss of critical information when vehicle trade studies are performed using “nominal” published cell-level performance metrics. Aircraft power demands rarely match these nominal power profiles, and aircraft designers lack the ability to accurately simulate the battery performance and temperature off-nominally unless the battery chemistry is well established. Conversely, battery suppliers have no generalized reference cases to publish more realistic performance metrics. This can lead to poor assumptions, such as aircraft studies assuming a fixed discharge efficiency of a battery, when in reality the usable energy in a pack is dependent on the power and thermal profile. Information needed to properly assess weight penalties for thermal management is also typically poorly characterized when assessing candidate batteries. This paper serves to better inform battery development, and similarly, provide aircraft designers with more realistic assumptions for applying knockdown margins in their designs. Detailed power and thermal performance estimates are provided, which provide a starting point for sizing power and thermal budgets using experimentally derived battery models. Results show that the X-57 battery-to-shaft efficiency is 77.3% for a particular optimized mission. Considering a 25% reserve on the battery capacity, this means that only roughly half of the original 55.3kWh ‘nominal’ pack energy can be converted to useful work during a mission. Further estimates on a clean-sheet VTOL optimization show an average 82.7% battery-to-shaft efficiency, using 98% peak efficiency inverters and 97.4% peak efficiency motors. Although higher battery efficiencies are possible, the resulting weight penalty negates improvement in vehicle performance. These trade-offs and resulting power profiles are provided as a starting point to better assess future battery designs.

Battery

Battery Cell-to-Pack Scaling Laws for Electric Aircraft

Battery pack gravimetric energy density is one of the most important, yet often miss-estimated design parameters for sizing all-electric aircraft. Proper accounting for thermal, structural, and operational safety margins are frequently lost when extrapolating performance from the cell level to the aircraft level. This paper summarizes the relevant engineering and certification details needed to better account for the penalties associated when assembling battery packs. The relationship between the cell and pack energy density is not linear, as is often assumed. Furthermore, the relationship varies depending on pack requirements, cell chemistry, and architecture. Parametric, high-fidelity models are used to determine optimal battery pack sizes over a range of conditions to better quantify technology scaling effects.

Battery Electric Aircraft

Battery Cell-to-Pack Scaling Trends for Electric Aircraft

Battery pack gravimetric energy density is one of the most important, yet often miss- estimated design parameters for sizing all-electric aircraft. Proper accounting for thermal, structural, and operational safety margins are frequently lost when extrapolating performance from the cell level to the aircraft level. This paper summarizes the relevant engineering and certification details needed to better account for the penalties associated when assembling battery packs. The relationship between the cell and pack energy density is not linear, as is often assumed. Furthermore, the relationship varies depending on pack requirements, cell chemistry, and architecture. Parametric, high-fidelity models are used to determine optimal battery pack sizes over a range of conditions to better quantify technology scaling effects.

Battery Electric Aircraft

Battery Evaluation Profiles for X-57 and Future Urban Electric Aircraft

Battery energy density is one of the most critical design parameters for sizing all-electric aircraft, however it’s easily overestimated. Establishing the effective, usable energy density is confused by varying degrees of margin needed to account for structural and thermal management between different cell chemistry and pack designs. Therefore, a better methodology is needed to fairly compare emerging battery technologies for electric aircraft. Currently, there is a loss of critical information when vehicle trade studies are performed using “nominal” published cell-level performance metrics. Aircraft power demands rarely match these nominal power profiles, and aircraft designers lack the ability to accurately simulate the battery performance and temperature off-nominally unless the battery chemistry is well established. Conversely, battery suppliers have no generalized reference cases to publish more realistic performance metrics. This can lead to poor assumptions, such as aircraft studies assuming a fixed discharge efficiency of a battery, when in reality the usable energy in a pack is dependent on the power and thermal profile. Information needed to properly assess weight penalties for thermal management is also typically poorly characterized when assessing candidate batteries. This paper serves to better inform battery development, and similarly, provide aircraft designers with more realistic assumptions for applying knockdown margins in their designs. Detailed power and thermal performance estimates are provided, which provide a starting point for sizing power and thermal budgets using experimentally derived battery models. Results show that the X-57 battery-to-shaft efficiency is 77.3% for a particular optimized mission. Considering a 25% reserve on the battery capacity, this means that only roughly half of the original 55.3kWh ‘nominal’ pack energy can be converted to useful work during a mission. Further estimates on a clean-sheet VTOL optimization show an average 82.7% battery-to-shaft efficiency, using 98% peak efficiency inverters and 97.4% peak efficiency motors. Although higher battery efficiencies are possible, the resulting weight penalty negates improvement in vehicle performance. These trade-offs and resulting power profiles are provided as a starting point to better assess future battery designs.

Battery Electric Aircraft

Unraveling the Complex History of Aqueous Alteration and Metamorphism in CV Chondrite, Camel Donga 040

Camel Donga (CD) 040 is a CV breccia collected from Australia in 1988. Initial studies of CD 040 revealed two lithologies, both containing chondrules up to 1 mm in diameter (some with fine-grained rims) and abundant troilite, but each with remarkably different olivine compositions. Lithology 1 was characterized as petrologic type 3 material, while lithology 2 was described as being “heated to ~1100°C”. CD 040 was initially classified as an ungrouped C3; however, subsequent analyses of oxygen isotopes and bulk rock compositions confirmed that both lithologies were CV chondrite material. Though CD 040 was one of the earliest examples of a CV chondrite containing metamorphosed material, it was never extensively studied. Here we report the results of a detailed study of CD 040, focusing primarily on the petrography and mineral chemistry of metamorphosed lithology.

T L Dunn

Boundary Layer Analysis of Shock Tube Flows

Shock tubes offer a controlled environment to reproduce kinetic and radiative phenomena characteristic of atmospheric entry flows under ground-test conditions. The boundary layer developing behind the incident shock wave determines the available test time, influences particle residence times important for similarity scaling, and can affect radiative energy transport. In this study, we couple a quasi-1D space marcher with the compressible boundary-layer equations to numerically compute the post-shock flow in a shock frame of reference for various test gas mixtures representative of different planetary atmospheres. The solvers are individually verified against CFD simulations and analytical correlations available in the literature. Coupled solutions are computed for a finite-rate chemistry in the boundary layer and a non-catalytic isothermal wall. Results yield refined estimates of the maximum separation distance, as well as insights into concentration profiles of relevant species within the boundary layer.

Andrea Fagnani

NASA Engineering Safety Center NASA Aerospace Flight Battery Systems Working Group 2007 Proactive Task Status

In 2007, the NASA Engineering Safety Center (NESC) chartered the NASA Aerospace Flight Battery Systems Working Group to bring forth and address critical battery-related performance/manufacturing issues for NASA and the aerospace community. A suite of tasks identifying and addressing issues related to Ni-H2 and Li-ion battery chemistries was submitted and selected for implementation. The current NESC funded are: (1) Wet Life of Ni-H2 Batteries (2) Binding Procurement (3) NASA Lithium-Ion Battery Guidelines (3a) Li-Ion Performance Assessment (3b) Li-Ion Guidelines Document (3b-i) Assessment of Applicability of Pouch Cells for Aerospace Missions (3b-ii) High Voltage Risk Assessment (3b-iii) Safe Charge Rates for Li-Ion Cells (4) Availability of Source Material for Li-Ion Cells (5) NASA Aerospace Battery Workshop This presentation provides a brief overview of the tasks in the 2007 plan and serves as an introduction to more detailed discussions on each of the specific tasks.

Manzo, Michelle A.

Initial Test Firing Results for Solid CO/GOX Cryogenic Hybrid Rocket Engine for Mars ISRU Propulsion Applications

ORBITEC is developing methods for producing, testing, and utilizing Mars-based ISRU fuel/oxidizer combinations to support low cost, planetary surface and flight propulsion and power systems. When humans explore Mars we will need to use in situ resources that are available, such as: energy (solar); gases or liquids for life support, ground transportation, and flight to and from other surface locations and Earth; and materials for shielding and building habitats and infrastructure. Probably the easiest use of Martian resources to reduce the cost of human exploration activities is the use of the carbon and oxygen readily available from the CO2 in the Mars atmosphere. ORBITEC has conducted preliminary R&D that will eventually allow us to reliably use these resources. ORBITEC is focusing on the innovative use of solid CO as a fuel. A new advanced cryogenic hybrid rocket propulsion system is suggested that will offer advantages over LCO/LOX propulsion, making it the best option for a Mars sample return vehicle and other flight vehicles. This technology could also greatly support logistics and base operations by providing a reliable and simple way to store solar or nuclear generated energy in the form of chemical energy that can be used for ground transportation (rovers/land vehicles) and planetary surface power generators. This paper describes the overall concept and the test results of the first ever solid carbon monoxide/oxygen rocket engine firing.

Eric E Rice

Planetary and Deep Space Requirements for Photovoltaic Solar Arrays

In the past 25 years, the majority of interplanetary spacecraft have been powered by nuclear sources. However, as the emphasis on smaller, low cost missions gains momentum, more deep space missions now being planned have baselined photovoltaic solar arrays due to the low power requirements (usually significantly less than 100 W) needed for engineering and science payloads. This will present challenges to the solar array builders, inasmuch as planetary requirements usually differ from earth orbital requirements. In addition, these requirements often differ greatly, depending on the specific mission; for example, inner planets vs. outer planets, orbiters vs. flybys, spacecraft vs. landers, and so on. Also, the likelihood of electric propulsion missions will influence the requirements placed on solar array developers. This paper will discuss representative requirements for a range of planetary and deep space science missions now in the planning stages. We have divided the requirements into three categories: Inner planets and the sun; outer planets (greater than 3 AU); and Mars, cometary, and asteroid landers and probes. Requirements for Mercury and Ganymede landers will be covered in the Inner and Outer Planets sections with their respective orbiters. We will also discuss special requirements associated with solar electric propulsion (SEP). New technology developments will be needed to meet the demanding environments presented by these future applications as many of the technologies envisioned have not yet been demonstrated. In addition, new technologies that will be needed reside not only in the photovoltaic solar array, but also in other spacecraft systems that are key to operating the spacecraft reliably with the photovoltaics.

C P Bankston

NASA Battery Working Group - 2007-2008: Battery Task Summary Report

This presentation provides a summary of the 2007-2008 NASA Battery Working Group efforts completed in support of the NASA Engineering Safety Center (NESC). The effort covered a series of pro-active tasks that address the following: Binding Procurements -- guidelines related to requirements for the battery system that should be considered at the time of contract award Wet Life of Ni-H2 Batteries -- issues/strategies for effective storage and impact of long-term storage on performance and life Generic Guidelines for Lithium-ion Safety, Handling and Qualification -- Standardized approaches developed and risk assessments (1) Lithium-ion Performance Assessment -- survey of manufacturers and capabilities to meet mission needs. Guidelines document generated (2) Conditions Required for using Pouch Cells in Aerospace Missions -- focus on corrosion, thermal excursions and long-term performance issues. Document defining requirements to maintain performance and life (3) High Voltage Risk Assessment -- focus on safety and abuse tolerance of battery module assemblies. Recommendations of features required for safe implementation (4) Procedure for Determination of Safe Charge Rates -- evaluation of various cell chemistries and recommendation of safe operating regimes for specific cell designs

Manzo, Michelle

Influence of Processing Parameters on the Mechanical Properties of 3D Printed Borosilicate Particulate Reinforced Polymer Composites

Emerging composite materials are expanding the potential of additive manufacturing and enabling applications previously restricted by traditional manufacturing methods. The multi-phase nature of these composite materials combined with the complex in-ternal geometry of additively manufactured parts have enabled unique behavior, and potentially new applications. Additionally, these materials can be pyrolyzed to create dense metal, ceramic, and glass parts with geometries typically not achievable by tra-ditional processes. Additive manufacturing of borosilicate glass-based systems can open new applications in nuclear engineering, astronomy, and bone regrowth therapy. To elucidate the process-parameter relationship of borosilicate-polylactic acid (PLA) composites, mechanical testing was conducted and compared with a pure polylactic acid polymer baseline. Test specimens were fabricated by fused-filament fabrication with minimal post-processing. Yield strength, ultimate strength, and elastic modulus were calculated from stress-strain curves. Optical and scanning electron microscopy were conducted to observe the specimen microstructure before and after testing. The highest compressive yield strength for the composite was 28.22 MPa, and the highest compressive yield strength for PLA was 49.30 MPa. Print orientation was found to benefit the composite material but have a detrimental effect on the pure matrix material. An elastic modulus of 2.66 GPa was recorded for the borosilicate-PLA composite at 100% infill, 1 shell wall, and layer lines parallel to compression axis. Microscopy revealed that lower modulus composite specimens had the particulates re-distributed within the matrix. Tensile testing was done according to a polymer testing standard, which caused difficulties obtaining consistent fracture within the gauge length.

mechanical testing

Updated global and regional trends of stratospheric ozone profiles

We present updated evaluation of stratospheric ozone profile trends in the 60° S–60°N latitude range using long-term ground-based and satellite climate data records, as well as simulations by chemistry-climate models. The trends are evaluated using the LOTUS (Long-term Ozone Trends and Uncertainties in the Stratosphere) regression model. Analyses of satellite data confirm the statistically significant positive ozone trends in the period 2000–2024 in the upper stratosphere of ~1–3% per decade, with larger trends at mid-latitudes compared to the tropics. The trends are slightly positive or close to zero in the middle stratosphere, and mostly negative, -1 to -2% per decade, in the lower stratosphere, but they are not statistically significant. The morphology and magnitude of ozone trends are similar to previous analyses (2000–2020 trends). Ozone trends in 2000–2024 predicted by chemistry-climate model simulations are in good agreement with combined satellite trends. In the upper stratosphere, models predict a slightly stronger ozone recovery than observations. In the lower stratosphere, both models and satellite observations report negative trends in the tropics, while modelled ozone trends are slightly positive at mid-latitudes. Ozone profile trends over several stations estimated from ground-based records capture the same overall vertical pattern of ozone trends as merged gridded satellite datasets. Analyses of regional ozone profile trends in 2003–2024 using merged satellite datasets confirmed the previous observations of a longitudinal structure in ozone trends in the NH mid-latitude stratosphere, with positive trends over Scandinavia and negative trends over Siberia. However, the magnitude of this dipole-like structure is reduced compared to previous analyses.

trends

Polyimide/Carbon Nanotube Composite Films for Electrostatic Charge Mitigation

Low color, space environmentally durable polymeric films with sufficient electrical conductivity to mitigate electrostatic charge (ESC) build-up have potential applications on large, deployable, ultra-light weight Gossamer spacecraft as thin film membranes on antennas, solar sails, thermal/optical coatings, multi-layer insulation blankets, etc.. The challenge has been to develop a method to impart robust electrical conductivity into these materials without increasing solar absorptivity (alpha ) or decreasing optical transparency or film flexibility. Since these spacecraft will require significant compaction prior to launch, the film portion of the spacecraft will require folding. The state-of-the-art clear, conductive coating (e.g. indium-tin-oxide, ITO) is brittle and cannot tolerate folding. In this report, doping a polymer with single-walled carbon nanotubes (SWNTs) using two different methods afforded materials with good flexibility and surface conductivities in the range sufficient for ESC mitigation. A coating method afforded materials with minimal effects on the mechanical, optical, and thermo-optical properties as compared to dispersal of SWNTs in the matrix. The chemistry and physical properties of these nanocomposites are discussed.

Smith, Joseph G., Jr.

Exploring the Model Design Space for Battery Health Management

Battery Health Management (BHM) is a core enabling technology for the success and widespread adoption of the emerging electric vehicles of today. Although battery chemistries have been studied in detail in literature, an accurate run-time battery life prediction algorithm has eluded us. Current reliability-based techniques are insufficient to manage the use of such batteries when they are an active power source with frequently varying loads in uncertain environments. The amount of usable charge of a battery for a given discharge profile is not only dependent on the starting state-of-charge (SOC), but also other factors like battery health and the discharge or load profile imposed. This paper presents a Particle Filter (PF) based BHM framework with plug-and-play modules for battery models and uncertainty management. The batteries are modeled at three different levels of granularity with associated uncertainty distributions, encoding the basic electrochemical processes of a Lithium-polymer battery. The effects of different choices in the model design space are explored in the context of prediction performance in an electric unmanned aerial vehicle (UAV) application with emulated flight profiles.

Saha, Bhaskar

Americium-Fuelled Radioisotope Stirling Generator Elegant Breadboard

High power solutions for spacecraft are becoming increasingly sought after in the new era of space exploration, with energy intensive in-situ lunar surface exploration becoming a key part of the roadmap for major space agencies, as well as commercial companies. Nuclear power provides the most feasible solution to achieve continued operation through the long lunar night, and in extended periods in Permanently Shadowed Regions (PSRs). Americium-241 (241Am) is used as the fuel of choice in European Radioisotope Power Systems (RPS). The University of Leicester have developed a number of systems using this fuel type, including a 200 Wth heat source. Building on existing international partnerships, the University of Leicester is continuing to work with NASA Glenn Research Center (GRC) to maximise the electrical output that can be generated from the heat source by progressing the radioisotope-Stirling generator concept to elegant breadboard level, building on the long heritage of dynamic power conversion developments at NASA Glenn. Presented in the following conference paper is the next iteration of the Americium-fuelled Radioisotope Stirling Generator (Am-RSG) Elegant Breadboard, following on from a successful technology demonstration design conducted at NASA Glenn in early 2025. The design laid-out in this paper is a more flight-like version of the technology demonstrator, and is intended to pair with the next generation of Stirling convertor technology, the SunPower Robust Stirling Converter (SRSC). The SRSC is able to operate more efficiently at lower thermal power levels than the previous Advanced Stirling Convertor (ASC), making it more suitable for the 241Am system.

Lunar

Optimization of a 10–Step Reduced CH₄/O₂ Combustion Mechanism for RDRE Applications

A 10-step, 9-species reduced mechanism for methane/oxygen combustion is evaluated and optimized for use in rotating detonation rocket engine (RDRE) simulations at an operating pressure of 10 bar. The mechanism is assessed against GRI-Mech 3.0 for ignition delay times, adiabatic equilibrium temperature and species, Chapman-Jouguet (CJ) detonation parameters, and laminar flame speed. A sequential Nelder–Mead optimization procedure is applied to the rate constants of reactions R1, R4, and R5, targeting ignition delay agreement over the equivalence ratio range φ = 1.0–1.4 and temperature range T = 1400–2000 K. The optimized mechanism achieves ignition delay agreement within 28% of GRI-Mech 3.0 for the temperature range relevant to RDRE operation (τ ≥ 5 μs). Adiabatic equilibrium temperatures and CJ detonation parameters are reproduced within 0.15% of GRI-Mech 3.0 values, confirming thermodynamic consistency of the mechanism. Laminar flame speed predictions deviate significantly from GRI-Mech 3.0, which is attributed to the absence of HO₂ chemistry in the reduced mechanism; this limitation does not affect RDRE simulation fidelity since laminar flame propagation is of secondary importance in RDREs.

Computational Fluid Dynamics