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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS2026

Smart Process Planning for Automated Fiber Placement

Many industries, including aerospace, automotive, wind energy, maritime, and sporting goods, rely on strong, lightweight materials called composites. These materials are made by layering fibers, which can come in the form of narrow strips or wider sheets, and setting them in a polymer matrix. One of the most advanced ways to make these parts is through automated fiber placement, where a machine lays down the fibers in precise patterns. This method can create very efficient and strong designs, but it is complex, expensive, and often depends heavily on the experience of skilled engineers. Today, the design, manufacturing, and inspection stages of composite production are usually handled separately. This separation means that important information, such as how a part will be built or what defects might occur, is not always shared between stages. As a result, parts may not be as lightweight, strong, or defect-free as possible, and the process can take longer and cost more. This research develops a smart process planning system that connects design, manufacturing, and inspection into one continuous process. Built as software that works with existing tools, the system can automatically plan how the fibers are placed, predicting and reducing defects while improving both manufacturability and strength. The system optimizes not only individual layers but also how defects are distributed across all layers, preventing them from stacking up in ways that weaken the final part. It also uses inspection results from completed parts to improve future designs, creating a feedback loop where each stage informs the others. The system was tested by designing a composite panel using this new approach and comparing it to a panel made with state-of-the-art manual planning methods. The results showed that the system could intentionally control where defects appeared and increase the efficiency of the planning process. By unifying design, manufacturing, and inspection, this research shows a way to make advanced composite manufacturing more efficient, consistent, and cost-effective. This approach lowers the barrier to using automated fiber placement and opens the door for its wider adoption not only in aerospace but also in industries such as automotive, wind energy, maritime, and sporting goods, where strong and lightweight structures are essential.

Computer-Aided Process Planning↗
NASA NTRS1998

Battery Systems for X-38 Crew Return Vehicle (CRV) and Deorbit Propulsion Stage (DPS)

A 28V 32 Ah cell Li/MnO2 and a 28V NiMH battery systems for the Deorbit Propulsion Stage (DPS) and the X-38 Crew Return Vehicle (CRV) are developed in Friwo-Silforkraft, Germany with the following objectives and approach: Provide safe battery designs for lowest volume and cost, and within schedule; Take advantage of less complex requests for V201 vs OPS CRV to simplify design and reduce cost; Use only existing commercial cell designs as building blocks for larger battery; Derive battery designs from the ASTRO-SPAS design which is the largest lithium battery design with Shuttle flight experience; Place maximum amount of battery energy on DPS; DPS battery is non rechargeable; and CRV batteries are rechargeable. This paper contains the following sections: a brief introduction on CRV requirements, CRV advantages over Soyuz, and X-38 programs; Battery objectives and approach; Battery requirements and groundrules (performance, on-orbit operation, etc); Design trades, solutions, redundancy plan, and margins; Envelope, size, and mass; Interfaces (structural, electrical & thermal); and Deviation from OPS CRV.

Darcy, Eric↗
NASA NTRS1988

Space Station battery system design and development

The Space Station Electric Power System will rely on nickel-hydrogen batteries in its photovoltaic power subsystem for energy storage to support eclipse and contingency operations. These 81-Ah batteries will be designed for a 5-year life capability and are configured as orbital replaceable units (ORUs), permitting replacement of worn-out batteries over the anticipated 30-year Station life. This paper describes the baseline design and the development plans for the battery assemblies, the battery ORUs and the battery system. Key elements reviewed are the cells, mechanical and thermal design of the assembly, the ORU approach and interfaces, and the electrical design of the battery system. The anticipated operational approach is discussed, covering expected performance as well as the processor-controlled charge management and discharge load allocation techniques. Development plans cover verification of materials, cells, assemblies and ORUs, as well as system-level test and analyses.

Haas, R. J.↗
NASA NTRS1985

Life cycle test results of a bipolar nickel hydrogen battery

A history is given of low Earth orbit (LEO) laboratory test data on a 6.5 ampere-hour bipolar nickel hydrogen battery designed and built at the NASA Lewis Research Center. The bipolar concept is a means of achieving the goal of producing an acceptable battery, of higher energy density, able to withstand the demands of low-Earth-orbit regimes. Over 4100 LEO cycles were established on a ten cell battery. It seems that any perturbation on normal cycling effects the cells performance. Explanations and theories of the battery's behavior are varied and widespread among those closely associated with it. Deep discharging does provide a reconditioning effect and further experimentation is planned in this area. The battery watt-hour efficiency is about 75 percent and the time averaged, discharge voltage is about 1.26 volts for all cells at both the C/4 and LEO rate. Since a significant portion of the electrode capacity has degraded, the LEO cycle discharges are approaching depths of 90 to 100 percent of the high rate capacity. Therefore, the low end-of-discharge voltages occur precipitously after the knee of the discharge curve and is more an indication of electrode capacity and is a lesser indicator of overall cell performance.

Cataldo, R. L.↗
NASA NTRS2022

Cryogenic Spray Quenching of A Simulated Propellant Storage Tank Wall With Heat Transfer Enhancement By A Thin-Film Coating and Flow Pulsing in Microgravity

Human space exploration to the Moon, Mars, and possibly asteroids is NASA’s biggest challenge for the new millennium. One of the critical elements to this mission is the effective, sufficient, and reliable supply of cryogenic propellant fluids. Future lower-earth-orbiting (LEO) propellant fuel depots and human-carrying orbital transfer spacecraft flying to the moon and Mars will have to utilize the high thrust and high efficiency of liquid cryogenic chemical propulsion or nuclear thermal propulsion. Efficient in-space tank-to-tank propellant transfer (propellant fuel depot to orbital transfer spacecraft) of cryogenic propellants is an enabling technology for the planned Crewed Mars Surface Mission. The transfer of cryogenic propellants in space, however, has yet to be accomplished, solely due to the unavailability of cryogenic quenching heat transfer data during chilldown (quenching) and filling of the propellant receiver tank in reduced gravity and microgravity as liquid propellant cannot be stored in a required liquid state until the tank is quenched down to the liquid temperature. Therefore, highly energy efficient thermal-fluid management breakthrough concepts to conserve and minimize the cryogen consumption during propellant transfer have become the focus of research and engineering development, especially for the deep-space mission to Mars. In this paper, we introduce such concepts and demonstrate their feasibility for cryogenic storage tank chilldown in parabolic flights under a simulated space microgravity condition. In order to maximize the storage tank chilldown efficiency for the least amount of cryogen consumption, the technology adopted included cryogenic spray cooling, Teflon thin-film coating of the simulated tank surface, and spray flow pulsing. The completed flight experiments successfully demonstrated that spray cooling is the most efficient cooling method for the tank chilldown in microgravity. In microgravity, Teflon coating alone can improve the efficiency up to 72% and the efficiency can be improved up to 59% by flow pulsing alone. However, Teflon coating together with flow pulsing was found to substantially enhance the chilldown efficiency in microgravity for up to 113%.

spray↗
NASA NTRS2026

Hyperspectral Detail Meets Radiometric Accuracy: A Foundational Reflected Solar Capability for the Coming Decade

Hyperspectral Earth-reflected solar measurements contain rich, detailed information about clouds, aerosols, and the atmosphere. This information compounds when paired with high, SI-traceable radiometric accuracy. Unlike spectral resolution, which can be resampled to coarser spectral resolutions, radiometric accuracy cannot be recovered once a measurement is made, making the choice to invest in this capability now a decision with lasting consequences for the climate record. CLARREO Pathfinder is demonstrating that this combination of hyperspectral sampling and benchmark-quality accuracy is achievable today, but no follow-on mission is currently planned within NASA's Earth Science Division portfolio, and the recent cancellation of the European Space Agency TRUTHS mission has heightened the urgency of sustaining this capability. We recommend prioritizing investment in a follow-on to CLARREO Pathfinder, along with dedicated support for the science community to fully exploit these measurements. This capability would reduce long-standing uncertainties in cloud feedback, aerosol forcing, and global energy imbalance, while providing a degradation-resistant, gap-resilient calibration foundation for the broader Earth observing system. Building on flight-proven technology and an engaged science community, this is a near-term, fiscally realistic opportunity to secure a foundational Earth observation capability for the coming decade.

satellite↗
NASA NTRSDate not supplied

NASA POWER: Providing Analysis-Ready, Cloud-Optimized Data for AI /ML Training and Applications in Earth Science

As global demand for sustainable development grows, the integration of Earth Observation (EO) data into decision making frameworks has become a primary objective for the scientific community. The NASA Prediction of Worldwide Energy Resources (POWER) project serves as a bridge between NASA EO data and the specialized needs of the renewable energy, sustainable infrastructure and agroclimatology communities. In this poster presentation we will present an overview of POWER data products and services along with its use in diverse research to decision-making workflows. By providing over 40 years of high-resolution historical, hourly and daily solar and meteorological data, POWER transforms satellite observations and global model reanalysis into actionable, Analysis-Ready Dataset (ARD). Currently, the project delivers over 250 industry-friendly parameters to the users from different NASA datasets like CERES SYN1Deg, MERRA-2, and IMERG alongside downscaled CMIP6 climate model data, fulfilling over 16 million requests from 50,000 unique users monthly. To ensure data quality and traceability, these parameters are rigorously validated against the ground-based observations from the Baseline Surface Radiation Network (BSRN) and the Global Surface Summary of the Day (GSOD) – these results will be discussed in the presentation. A newly introduced web-based PaRameter Uncertainty ViEwer (PRUVE) tool will be presented that provides an online validation platform to the users that benchmarks satellite-based and assimilation data products against these surface measurements. To reduce technical barriers to data adoption, POWER data is accessible through RESTful APIs, ESRI ArcGIS Image Services, a web-based Data Access Viewer tool, allowing users to visualize, validate and apply the dataset. For efficient data delivery POWER data is cloud-optimized into Zarr datastore accessible through NASA managed Amazon S3 ensures high-performance allowing users to integrate EO directly into operational pipelines. These customized services will be presented. Use cases from application will be presented from the energy sector - such as for design of generation systems, performance monitoring of solar power plants, in infrastructure sector- optimizing building energy efficiency and thermal comfort, in agriculture – such as driving crop simulation and yield forecasting models to enable climate resilient farming. Furthermore, the shift toward machine learning (ML) in EO research that has positioned POWER as a key provider for training datasets which will be discussed. Use-cases will be presented to showcase how NASA data is enabling the development of predictive tools for climate variability and resource management. The poster will present POWER’s future plans including technology development to enhance data traceability and reproducibility and improving I/O performance to support the rapid integration of new EO products, ensuring that POWER remains a robust scalable backend for the evolving landscape of AI-driven Earth Science. Additionally, POWER is developing an AI Agent and an MCP-Server to enable industry AI-Agentic workflows.

Neha Khadka↗
NASA NTRS2018

International Space Station Lithium-Ion Battery Status

When originally launched, the International Space Station (ISS) primary Electric Power System (EPS) used Nickel-Hydrogen (Ni-H2) batteries to store electrical energy. The electricity for the space station is generated by its solar arrays, which charge batteries during insolation for subsequent discharge during eclipse. The Ni-H2 batteries were designed to operate for ten years at a 35 percent depth of discharge (DOD) maximum during normal operation in a Low Earth Orbit. For service beyond that period, upgraded Li-Ion Orbital Replacement Units (ORUs) were designed. These are the largest Li-Ion batteries ever utilized for a human rated spacecraft. With the oldest 12 Ni-H2 battery ORUs cycling since September 2006, the first set of six was replaced by Li-Ion batteries in December 2016; the second set of six is planned for replacement in September 2018. This paper will include an overview of the ISS Li-Ion battery system architecture, on-orbit status of the first 6 batteries, start up of the second 6 batteries, and the status of the Li-Ion cell and ORU life cycle testing.

International Space Station↗
NASA NTRS2003

Introduction to Radiation Issues for International Space Station Extravehicular Activities: Chapter 1

The International Space Station (ISS) provides significant challenges for radiation protection of the crew due to a combination of circumstances including: the extended duration of missions for many crewmembers, the exceptionally dynamic nature of the radiation environment in ISS orbit, and the necessity for numerous planned extravehicular activities (EVA) for station construction and maintenance. Radiation protection requires accurate radiation dose measurements and precise risk modeling of the transmission of high fluxes of energetic electrons and protons through the relatively thin shielding provided by the space suits worn during EVA. Experiments and analyses have been performed due to the necessity to assure complete radiation safety for the EVA crew and thereby ensure mission success. The detailed characterization described of the material and topological properties of the ISS space suits can be used as a basis for design of space suits used in future exploration missions. In radiation protection practices, risk from exposure to ionizing radiation is determined analytically by the level of exposure, the detrimental quality of the radiation field, the inherent radiosensitivity of the tissues or organs irradiated, and the age and gender of the person at the time of exposure. During low Earth orbit (LEO) EVA, the relatively high fluxes of low-energy electrons and protons lead to large variations in exposure of the skin, lens of the eye, and tissues in other shallow anatomical locations. The technical papers in this publication describe a number of ground-based experiments that precisely measure the thickness of the NASA extravehicular mobility unit (EMU) and Russian Zvezda Orlan-M suits using medical computerized tomography (CT) X-ray analysis, and particle accelerator experiments that measure the minimum kinetic energy required by electrons and photons to penetrate major components of the suits. These studies provide information necessary for improving the understanding of the current ISS space suits and provide insights into improved approaches for the design of future suits. This chapter begins with a summary of the dynamic ionizing radiation environment in LEO space and introduces the concepts and quantities used to quantify exposure to space radiation in LEO. The space suits used for EVA and the experimental partial human phantom are described. Subsequent chapters report results from measured charged particle fields before and after incident protons and secondary particles are transported through the space suits and into organs and tissues.

M R Shavers↗
NASA NTRSDate not supplied

An Efficient Approach to Collect Inlet Characterization Data

This report considers a novel process to acquire performance data for supersonic mixed compression inlets that is faster, and therefore less costly, than the previous one. In the previous process, measurements were recorded in discrete increments. The backpressuring actuator was advanced, there was a pause to allow for airflow fluctuations to diminish, and then the measurements were recorded. While this process was methodical, reliable and accurate, it consumed significant wind-on time. In general, high-speed wind tunnels are expensive to operate considering maintenance, energy and human resource requirements. Furthermore, many facilities, such as blowdown wind tunnels, are limited in the duration that they can maintain the desired test condition. Consequently, a quick method to collect the measurements is desired. A favored approach has the actuator moving in a continuous fashion with measurements recorded as the actuator continuously progresses through the increment points. This approach, identified as the dynamic inlet characteristic data acquisition procedure, uses in situ dynamic high-speed pressure sensors to measure pressure signals. While faster, continuous movement adds dynamic effects to the data. To better understand these dynamic effects and other potential influences, a study was undertaken to compare wind tunnel measurements taken at discrete actuator position points with data gathered during continuous actuator movement. Specially, plots of inlet pressure recovery versus mass capture ratio, or total pressure characteristic curves, were examined. The data were measured during experiments in the NASA Glenn Research Center Abe Silverstein 10- by 10-Foot Supersonic Wind Tunnel (SWT) with an inlet propulsion test article. In this report, the wind tunnel experiment and the study objectives are described. The processes to reduce the data and for analysis are explained. A discussion of the results along with features noted in the data is given. Finally, conclusions from this study that may be used to guide future wind tunnel experiment planning are presented.

Inlet↗
NASA NTRSDate not supplied

An Efficient Approach to Collect Inlet Characterization Data

This report considers a novel process to acquire performance data for supersonic mixed compression inlets that is faster, and therefore less costly, than the previous one. In the previous process, measurements were recorded in discrete increments. The backpressuring actuator was advanced, there was a pause to allow for airflow fluctuations to diminish, and then the measurements were recorded. While this process was methodical, reliable and accurate, it consumed significant wind-on time. In general, high-speed wind tunnels are expensive to operate considering maintenance, energy and human resource requirements. Furthermore, many facilities, such as blowdown wind tunnels, are limited in the duration that they can maintain the desired test condition. Consequently, a quick method to collect the measurements is desired. A favored approach has the actuator moving in a continuous fashion with measurements recorded as the actuator continuously progresses through the increment points. This approach, identified as the dynamic inlet characteristic data acquisition procedure, uses in situ dynamic high-speed pressure sensors to measure pressure signals. While faster, continuous movement adds dynamic effects to the data. To better understand these dynamic effects and other potential influences, a study was undertaken to compare wind tunnel measurements taken at discrete actuator position points with data gathered during continuous actuator movement. Specially, plots of inlet pressure recovery versus mass capture ratio, or total pressure characteristic curves, were examined. The data were measured during experiments in the NASA Glenn Research Center Abe Silverstein 10- by 10-Foot Supersonic Wind Tunnel (SWT) with an inlet propulsion test article. In this report, the wind tunnel experiment and the study objectives are described. The processes to reduce the data and for analysis are explained. A discussion of the results along with features noted in the data is given. Finally, conclusions from this study that may be used to guide future wind tunnel experiment planning are presented.

Data Acquisition↗