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NASA NTRS1989

Evaluation of on-board hydrogen storage methods for hypersonic vehicles

Hydrogen is the foremost candidate as a fuel for use in high speed transport. Since any aircraft moving at hypersonic speeds must have a very slender body, means of decreasing the storage volume requirements below that for liquid hydrogen are needed. The total performance of the hypersonic plane needs to be considered for the evaluation of candidate fuel and storage systems. To accomplish this, a simple model for the performance of a hypersonic plane is presented. To allow for the use of different engines and fuels during different phases of flight, the total trajectory is divided into three phases: subsonic-supersonic, hypersonic and rocket propulsion phase. The fuel fraction for the first phase is found be a simple energy balance using an average thrust to drag ratio for this phase. The hypersonic flight phase is investigated in more detail by taking small altitude increments. This approach allowed the use of flight profiles other than the constant dynamic pressure flight. The effect of fuel volume on drag, structural mass and tankage mass was introduced through simplified equations involving the characteristic dimension of the plane. The propellant requirement for the last phase is found by employing the basic rocket equations. The candidate fuel systems such as the cryogenic fuel combinations and solid and liquid endothermic hydrogen generators are first screened thermodynamically with respect to their energy densities and cooling capacities and then evaluated using the above model.

Akyurtlu, Ates↗

DOE OSTI2023

Conservation of Helium while Maintaining High System Purity

Recent helium shortages and helium price increases have lead to an increased emphasis being placed on conserving helium. The need to conserve helium must be balanced with need to maintain the high levels of purity necessary to prevent operational problems caused by contamination. Helium losses and contamination control are especially important for test stands that have cryogenic distribution systems operating continuously with frequent changeover of cryogenic temperature components that are being tested. This paper describes a mathematical model to estimate the quantity of helium lost and the purity of the helium after the pump and backfill procedure is complete. The process to determine the optimal time during pump down to cut off pumping and start backfilling is described. There is a tradeoff between trying to achieve the lowest possible pressure during pumping and the quantity of air leaking into the volume while pumping is occurring. An additional benefit of careful selection of pump and backfill parameters in conjunction with real-time pressure monitoring can reduce the labor and time required to complete a successful pump and backfill procedure. This paper is intended to be a tool for engineers to review their pump and backfill procedures and measured data to optimize helium losses, system purity, and labor required.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2023

Conservation of Helium while Maintaining High System Purity

Recent helium shortages and helium price increases have lead to an increased emphasis being placed on conserving helium. The need to conserve helium must be balanced with need to maintain the high levels of purity necessary to prevent operational problems caused by contamination. Helium losses and contamination control are especially important for test stands that have cryogenic distribution systems operating continuously with frequent changeover of cryogenic temperature components that are being tested. This paper describes a mathematical model to estimate the quantity of helium lost and the purity of the helium after the pump and backfill procedure is complete. The process to determine the optimal time during pump down to cut off pumping and start backfilling is described. There is a tradeoff between trying to achieve the lowest possible pressure during pumping and the quantity of air leaking into the volume while pumping is occurring. An additional benefit of careful sel ection of pump and backfill parameters in conjunction with real-time pressure monitoring can reduce the labor and time required to complete a successful pump and backfill procedure. This paper is intended to be a tool for engineers to review their pump and backfill procedures and measured data to optimize helium losses, system purity, and labor required.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

NASA NTRS1986

Non-intrusive speed sensor

In Phase I of the Non-Intrusive Speed Sensor program, a computerized literature search was performed to identify candidate technologies for remote, non-intrusive speed sensing applications in Space Shuttle Main Engine (SSME) turbopumps. The three most promising technologies were subjected to experimental evaluation to quantify their performance characteristics under the harsh environmental requirements within the turbopumps. Although the infrared and microwave approaches demonstrated excellent cavitation immunity in laboratory tests, the variable-source magnetic speed sensor emerged as the most viable approach. Preliminary design of this speed sensor encountered no technical obstacles and resulted in viable and feasible speed nut, sensor housing, and sensor coil designs. Phase II of this program developed the variable-source magnetic speed sensor through the detailed design task and guided the design into breadboard fabrication. The speed sensor and its integral speed nut were evaluated at both unit and system level testing. The final room-temperature and cryogenic spin testing of the hardware demonstrated that the sensor was capable of generating sufficient output signal to enable remote speed sensing from 1500 to 40000 rpm over a speed nut/sensor separation of 3.5 inches.

Wyett, L.↗

NASA NTRS1986

Evaluation of transfer films of Salox M on 440C for HPOTP bearing cage applications, task 119

The objective of the task was to evaluate the suitability of a bronze-filled polytetra fluoroethylene (Salox M) as the cage material in Space Shuttle Main Engine (SSME) high pressure oxygen turbo pump (HPOTP) bearings. The role of the cage pocket material will be to provide a transferred lubricating interface at the ball-race contact region. A series of experiments was conducted which involved block-on-ring tests (the block was the polytetrafluoroethylene (PTFE) -filled material and the ring was through-hardened 440C steel) and high speed traction tests of two 440C disks with one disk rubbed with a PTFE block to generate a transfer film. Measurements included post test visual observations of the condition of the 440C, wear rate measurements of the blocks, and traction measurements between the disks. It was observed that both Salox M and glass-filled PTFE (Armalon) transferred PTFE to 440C at cryogenic temperatures. Bronze is also transferred to uncoated 440C from the Salox M. At room temperature no PTFE transfer was observed in the high speed disk tests due to severe frictional heating, although bronze transfer still occurred with the bronze-PTFE Salox M material. Since the bearing will operate at cryogenic temperature, transfer films are very probable. Salox M wore slightly, although probably tolerably, more than glass-filled PTFE against 440C. However, Salox M is clearly less abrasive to 440C than is the glass-filled material. When the surface layer of PTFE is depleted from the glass-filled material, the glass fibers tend to seriously abrade the steel. This problem does not occur with Salox M. The surface roughness studies indicate that smooth balls are quite reasonable for transfer films. No significant difference in wear rates of the candidate cage materials was observed when the 440C surface finish was increased from 0.025 micron to 0.1 micron cla. At higher levels of roughness, the wear rate increased. Two surface coatings (MoS2 and TiN) were tested. The surface coatings tended to reduce the Salox M wear rate and reduce bronze transfer. PTFE transfer at cryogenic temperatures still occurred with the surface coatings. Two cage design concepts are presented utilizing Salox M material. One design involves a metal-reinforced Salox M cage, while the second design uses Salox M inserts in a metal structure.

Barber, S. A.↗

NASA NTRS2012

Stability Analysis of Intertank Formed Skin/Stringer Compression Panel with Simulated Damage

The External Tank (ET) is a component of the Space Shuttle launch vehicle that contains fuel and oxidizer. During launch, the ET supplies the space shuttle main engines with liquid hydrogen and liquid oxygen. In addition to supplying fuel and oxidizer, it is the backbone structural component of the Space Shuttle. It is comprised of a liquid hydrogen (LH2) tank and a liquid oxygen (LOX) tank, which are separated by an Intertank. The Intertank is a stringer-stiffened cylindrical structure with hat-section stringers that are roll formed from aluminum-lithium alloy Al-2090. Cracks in the Intertank stringers of the STS-133 ET were noticed after a November 5, 2010 launch attempt. The cracks were approximately nine inches long and occurred on the forward end of the Intertank (near the LOX tank), along the fastener line, and were believed to have occurred while loading the ET with the cryogenic propellants. These cracks generated questions about the structural integrity of the Intertank. In order to determine the structural capability of the Intertank with varying degrees of damage, a finite element model (FEM) simulating a 1995 compression panel test was analyzed and correlated to test data. Varying degrees of damage were simulated in the FEM, and non-linear stability analyses were performed. The high degree of similarity between the compression panel and the Intertank provided confidence that the ET Intertank would have similar capabilities.

Harper, David W.↗

NASA NTRS2026

Hydrofluoroether (HFE) Cleaning Fluid Replacement and Qualification

This NASA Engineering and Safety Center (NESC) Technical Assessment Report addresses the urgent need to identify, test, and qualify replacement cleaning solvents and technologies following 3M’s decision to discontinue production of hydrofluoroether (HFE) products, including Novec HFE-7100, by the end of 2025. HFE-7100 is widely used across NASA for precision cleaning of ground and flight hardware, especially in oxygen system components, and as a heat transfer fluid in high-power-density thermal control systems. The assessment evaluates commercially available replacement solvents, alternative cleaning technologies, and their compatibility with NASA’s operational requirements. Key findings include the identification of viable solvent replacements, their performance in contaminant removal, materials compatibility, and oxygen system safety. The report also explores novel cleaning approaches, including aqueous, supercritical CO₂, cryogenic aerosol, plasma, UV-ozone, magnetically optimized fluids, and induced charge active filtration, highlighting their merits, limitations, and readiness for NASA adoption. The NESC provides recommendations for solvent selection, facility adaptation, and continued technology maturation to ensure mission continuity and regulatory compliance.

Alternative Cleaning Technologies↗

NASA NTRSDate not supplied

Obtaining cryogenic molecular transport data for analysis

The James Webb Space Telescope (JWST) has a primary mirror, made of 18 segments, and a secondary mirror (SM) that are used to direct the light of desired targets. While on orbit, the secondary mirror assembly (SMA) was stowed for approximately 10 days and was subject to molecular contamination outgassing from the cavity of the secondary mirror support structure (SMSS) in-board hinge (IBH) which contains cables, motors, resolvers, and coatings. The main concern during this period before SMA deployment is the accumulation of ice due to the lack of a heater on the SMA. The temperature differentials between the IBH surfaces and SMA could cause redistribution of contaminants. To address this concern, single layer insulation (SLI) was used to create adequate venting and path redirection of outgassing from the IBH. Two separate thermal vacuum tests were performed to quantify this contamination: one Z307 ASTM E 1559 materials test of the radiator paint used on the motor of the IBH and a separate test on a primary mirror backplane assembly (PMBA) qualification engineering test unit (ETU) of the IBH. These tests approximately followed the predicted SMA pre-deployment thermal environment. To quantify source rates in case of a leak, the motor and resolver sides were separated and quartz crystal microbalances (QCM) were used to measure the deposition of water. The SLI redesign and implementation and outgassing measurements to understand leak effects from the IBH were essential to mitigate the deposition of contamination on the SMA.

James Webb Space Telescope, contamination, cleanro↗

NASA NTRSDate not supplied

Obtaining Cryogenic Molecular Transport Data for Analysis

James Webb Space Telescope↗

DOE OSTI2025

Experimental and Computational Insights into the Structural Dynamics of the Fc Fragment of IgG1 Subtype from Biosimilar VEGF‐Trap

The constant fragment (Fc) of the immunoglobulin G1 (IgG1) subtype is increasingly recognized as a crucial scaffold in the development of advanced therapeutics due to its enhanced specificity, efficacy, and extended half‐life. A prime example is VEGF‐Trap (Aflibercept), a recombinant fusion protein that merges the Fc region of the IgG1 subtype with the binding domains of vascular endothelial growth factor receptors (VEGFR)‐1 and VEGFR‐2. The Fc region's role in N‐glycosylation is particularly important, as it significantly influences protein stability. Herein, the first near‐physiological temperature structures of the N‐glycan‐bound Fc fragment of IgG1 subtype from a biosimilar VEGF‐Trap are presented, determined using the SPring‐8 Angstrom Compact free electron LAser (SACLA) and the Turkish Light Source (Turkish DeLight). Comparative analysis with cryogenic structures, including existing data, reveals alternate conformations within the glycan‐binding pocket. Furthermore, molecular dynamics simulations indicate the presence of a high degree of structural plasticity, explaining how the protein adapts its structure through conformational changes. The observed structural fluctuations/conformational changes demonstrate the effect of N‐glycans on protein stability. These findings offer new insights into the molecular basis of Fc‐mediated functions and provide valuable information for the design of next‐generation therapeutics.

60 APPLIED LIFE SCIENCES↗

NASA NTRS2012

Overview and Status of the James Webb Space Telescope Observatory

The James Webb Space Telescope (JWST) is a large aperture (6.5 meter), cryogenic space telescope with a suite of near and mid-infrared instruments spanning the wavelength range of 0.6 microns to 28 microns. JWST's primary science goals are to detect and characterize the first galaxies, study the assembly of galaxies, star formation, and the formation of evolution of planetary systems. JWST has a unique design based on the concept of passive cooling by means of a multi-layer sunshield to achieve the telescope's cryogenic operating temperature. Each of the five layers of the sunshield is approximately the size of a tennis court, and made of aluminized kapton. By maintaining an observatory attitude whereby the sunshield keeps the telescope in the shade from the sun's rays, the telescope and science instruments can operate at cryogenic temperature (-40 K). On the sun facing side of the observatory the spacecraft bus houses most of the electronic sub-systems, and provides a platform for the solar array and communications hardware. JWST is sufficiently large that it cannot fit inside .the fairing of its Ariane 5 launcher without being stowed in a more compact configuration, so the ability to deploy its major SUb-systems such as the telescope optics and sunshield after launch are another major feature of the observatory. Development of observatory is making rapid progress as major hardware SUb-systems nearcompletion. Polishing of the JWST telescope mirrors is complete with 18 primary mirror segments, the secondary mirror, tertiary and fine steering mirror all gold coated and through acceptance testing. Engineering test articles of each sunshield membrane layer are underway. The first layer 3 membrane is complete and is undergoing testing to evaluate its tensioned shape for compliance with alignment tolerances. As each major SUb-system is tested, the expected scientific performance of the observatory can be evaluated using test results and integrated system models of the observatory. We will discuss key performance parameters of the observatory, including thermal performance, image quality, sensitivity, and the ability to achieve background-limited observations. The observatory deployment after launch will also be discussed in the context of recent sub-system testing of deployment mechanisms.

Clampin, Mark↗

NASA NTRS2002

Data Acquisition and Control Systems Laboratory

The Data Acquisition and Control Systems (DACS) Laboratory is a facility at Stennis Space Center that provides an off test-stand capability to develop data-acquisition and control systems for rocket-engine test stands. It is also used to train new employees in state-of-the-art systems, and provides a controlled environment for troubleshooting existing systems, as well as the ability to evaluate the application of new technologies and process improvements. With the SSC propulsion testing schedules, without the DACS Laboratory, it would have been necessary to perform most of the development work on actual test systems, thereby subjecting both the rocket-engine testing and development programs to substantial interference in the form of delays, restrictions on modifications of equipment, and potentially compromising software configuration control. The DACS Laboratory contains a versatile assortment of computer hardware and software, digital and analog electronic control and data-acquisition equipment, and standard electronic bench test equipment and tools. Recently completed Control System development and software verification projects include support to the joint NASA/Air Force Integrated Powerhead Demonstration (IPD) LOX & LH2 PreBurner and Turbopump ground testing programs. In other recent activities, the DACS Laboratory equipment and expertise have supported the off-stand operation of high-pressure control valves to correct valve leak problems prior to installation on the test stand. Future plans include expanding the Laboratory's capabilities to provide cryogenic control valve characterization prior to installation, thereby reducing test stand activation time.

Holland, Randy↗

DOE OSTI2025

Monofluorinated acetal electrolyte for high-performance lithium metal batteries

High degree of fluorination for ether electrolytes has resulted in improved cycling stability of lithium metal batteries due to stable solid electrolyte interphase (SEI) formation and good oxidative stability. However, the sluggish ion transport and environmental concerns of high fluorination degree drive the need to develop less fluorinated structures. Here, we depart from the traditional ether backbone and introduce bis(2-fluoroethoxy)methane (F2DEM), featuring monofluorination of the acetal backbone. High coulombic efficiency and stable long-term cycling in Li||Cu half cells can be achieved with F2DEM even under fast Li metal plating conditions. The performance of F2DEM is further compared with diethoxymethane (DEM) and 2-[2-(2,2-difluoroethoxy)ethoxy]-1,1,1-trifluoroethane (F5DEE). A significantly lower overpotential is observed with F2DEM, which improves energy efficiency and enables its application in high-rate conditions. Comparative studies of F2DEM with DEM and F5DEE in anode-free lithium iron phosphate (LiFePO4) LFP pouch cells and high-loading LFP coin cells further show improved capacity retention of F2DEM electrolyte, demonstrating its practical applicability. More importantly, we also extensively investigate the underlying mechanism for the superior performance of F2DEM through various techniques, including X-ray photoelectron spectroscopy, scanning electron microscopy, cryogenic electron microscopy, focused ion beam, electrochemical impedance spectroscopy, and titration gas chromatography. Overall, F2DEM facilitates improved Li deposition morphology with reduced amount of dead Li. This enables F2DEM to show superior performance, especially under higher charging and slower discharging rate conditions.

25 ENERGY STORAGE↗

NASA NTRS2023

The Design, Verification and Performance of the James Webb Space Telescope

The James Webb Space Telescope (JWST) is NASA’s flagship mission successor to the highly successful Hubble Space Telescope. It is an infrared observatory featuring a cryogenic 6.6 m aperture, deployable Optical Telescope Element (OTE) with a payload of four science instruments (SIs) assembled into an Integrated Science Instrument Module (ISIM) that provide imagery and spectroscopy in the near-infrared band between 0.6 and 5 μm and in the mid-infrared band between 5 and 28.1 μm. JWST was successfully launched on 2021 December 25 aboard an Ariane 5 launch vehicle. All 50 major deployments were successfully completed on 2022 January 8. The observatory performed all midcourse correction maneuvers and achieved its operational mission orbit around the Sun–Earth second Lagrange point (L2). All commissioning and calibration activities have been completed, and JWST has begun its science mission. This paper will provide a description of the driving requirements and their technical challenges, the engineering processes involved in the design formulation, the resulting observatory design, the verification programs that proved it to be flightworthy, and the measured on-orbit performance of the observatory. Since companion papers will describe the details of the OTE and SIs, this paper will concentrate on describing the key features of the observatory architecture that accommodates these elements, particularly those features and capabilities associated with accommodating the radiometric and image-quality performance.

Galaxy evolution↗

NASA NTRS1975

Integrated auxiliary propulsion for the Space Tug

This paper summarizes the results of a design study which considered several possible methods for applying the liquid-liquid cryogenic oxygen/hydrogen auxiliary propulsion concept to the Space Tug. This concept, which is based on maintaining the propellant in the liquid phase from storage to thruster inlet, is much simpler than previous oxygen/hydrogen systems which converted the propellant to vapor for distribution to the thrusters. The paper describes the selected liquid-liquid concept which is an integrated design that uses the Tug main propulsion tanks as a propellant source. The characteristics of this integrated system are compared with dedicated storable propellant systems. The integrated concept is found to have only slightly superior mission payload performance, but provides inherent vehicle versatility through the interchangeable availability of main and auxiliary propellant. Propellant interchange also was found to permit the auxiliary system to provide abort backup capability in the event of most main engine failures. This capability implies Tug program cost savings which more than offset the higher development costs of the integrated auxiliary propulsion system.

Nichols, J. F.↗

DOE OSTI2026

Radioisotope dating of nuclear materials using cryogenic decay energy spectrometry

Cryogenic decay energy spectrometry provides high energy resolution and enables absolute decay counting, offering an alternative measurement technique for radiochronometry. A cryogenic decay energy spectrometry experiment was conducted using a magnetic microcalorimeter to determine the age of a plutonium sample. The energy resolution was measured at 0.05% from 5 to 6 MeV. The time since sample purification was determined using the measured concentration ratio of the 241 Am/ 241 Pu radiochronometer. Sample age estimates based on 241 Pu alpha-decay and beta-decay counts, along with 241 Am decay counts, align with the expected sample age within expanded uncertainty (k = 2), supporting the accuracy of cryogenic decay energy spectrometry as a radiochronometric method.

and nuclear chemistry↗

NASA NTRS1996

High Leverage Space Transportation System Technologies for Human Exploration Missions to the Moon and Beyond

The feasibility of returning humans to the Moon by 2004, the 35th anniversary of the Apollo 11 landing, is examined assuming the use of existing launch vehicles (the Space Shuttle and Titan 4B), a near term, advanced technology space transportation system, and extraterrestrial propellant--specifically 'lunar-derived' liquid oxygen or LUNOX. The lunar transportation system (LTS) elements consist of an expendable, nuclear thermal rocket (NTR)-powered translunar injection (TLI) stage and a combination lunar lander/Earth return vehicle (LERV) using cryogenic liquid oxygen and hydrogen (LOX/LH2) chemical propulsion. The 'wet' LERV, carrying a crew of 2, is configured to fit within the Shuttle orbiter cargo bay and requires only modest assembly in low Earth orbit. After Earth orbit rendezvous and docking of the LERV with the Titan 4B-launched NTR TLI stage, the initial mass in low Earth orbit (IMLEO) is approx. 40 t. To maximize mission performance at minimum mass, the LERV carries no return LOX but uses approx. 7 t of LUNOX to 'reoxidize' itself for a 'direct return' flight to Earth followed by an 'Apollo-style' capsule recovery. Without LUNOX, mission capability is constrained and the total LTS mass approaches the combined Shuttle-Titan 4B IMLEO limit of approx. 45 t even with enhanced NTR and chemical engine performance. Key technologies are discussed, lunar mission scenarios described, and LTS vehicle designs and characteristics are presented. Mission versatility provided by using a small 'all LH2' NTR engine or a 'LOX-augmented' derivative, either individually or in clusters, for outer planet robotic orbiter, small Mars cargo, lunar 'commuter', and human Mars exploration class missions is also briefly discussed.

Borowski, Stanley K.↗

DOE OSTI2026

Strain-Modified Raman Responses in Monolayer MoS 2 Nanobubbles Resolved at 5 nm

The formation of nanoscale bubbles is an unavoidable consequence during the transfer of two-dimensional materials onto target substrates, driven by van der Waals interactions at the interface. While often viewed as imperfections, these nanoscale bubbles have garnered considerable scientific interest due to the substantial in-plane strain gradients they induce, which in turn give rise to a variety of intriguing optoelectronic effects, particularly in semiconducting transition metal dichalcogenides. Determining and analyzing the strain distribution within nanobubbles at the nanoscale is crucial for advancing our understanding of these underlying strain-induced effects. Here, we present a high-resolution scanning tunneling microscopy-based tip-enhanced Raman spectroscopic investigation of localized nanoscale strain distribution within the nanobubbles formed between monolayer MoS 2 and Au interface. By employing cryogenic temperature (78 K), we successfully differentiate the nanoscale Raman signatures between nanobubble edge and pristine MoS 2 . We verify a maximum tensile strain of ∽1.15–1.34% at the nanobubble edge, which gradually diminishes toward the center, yielding a cross-sectional strain profile consistent with a doughnut-shaped distribution. Furthermore, we report to achieve ∽5 nm spatial resolution in probing such edge-localized strain within the nanobubble. In addition, comparative average strain analysis of such MoS 2 nanobubbles is conducted via geometric mechanistic analysis such as membrane and nonlinear plate theories, providing key insight into the geometric nature near the bubble edge. Our work provide fundamental information about strain-induced nanoscale chemical understanding of 2D materials on the nanometer scale, paving the way for practical applications of nanobubbles in strain-engineered optoelectronic devices.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗