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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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Develop a highly integrated and novel unitized reversible fuel cell (URFC) system that enables reliable, long duration energy storage at significantly higher energy density than state-of-the-art systems.
The Thermal Energy Storage (TES) experiments are designed to provide data to help researchers understand the long-duration microgravity behavior of thermal energy storage fluoride salts that undergo repeated melting and freezing. Such data, which have never been obtained before, have direct application to space-based solar dynamic power systems. These power systems will store solar energy in a thermal energy salt, such as lithium fluoride (LiF) or a eutectic of lithium fluoride/calcium difluoride (LiF-CaF2) (which melts at a lower temperature). The energy will be stored as the latent heat of fusion when the salt is melted by absorbing solar thermal energy. The stored energy will then be extracted during the shade portion of the orbit, enabling the solar dynamic power system to provide constant electrical power over the entire orbit. Analytical computer codes have been developed to predict the performance of a spacebased solar dynamic power system. However, the analytical predictions must be verified experimentally before the analytical results can be used for future space power design applications. Four TES flight experiments will be used to obtain the needed experimental data. This article focuses on the flight results from the first experiment, TES-1, in comparison to the predicted results from the Thermal Energy Storage Simulation (TESSIM) analytical computer code.
NASA's Exploration Technology Development Program funded the Energy Storage Project to develop battery and fuel cell technology to meet the expected energy storage needs of the Constellation Program for human exploration. Technology needs were determined by architecture studies and risk assessments conducted by the Constellation Program, focused on a mission for a long-duration lunar outpost. Critical energy storage needs were identified as batteries for EVA suits, surface mobility systems, and a lander ascent stage; fuel cells for the lander and mobility systems; and a regenerative fuel cell for surface power. To address these needs, the Energy Storage Project developed advanced lithium-ion battery technology, targeting cell-level safety and very high specific energy and energy density. Key accomplishments include the development of silicon composite anodes, lithiated-mixed-metal-oxide cathodes, low-flammability electrolytes, and cell-incorporated safety devices that promise to substantially improve battery performance while providing a high level of safety. The project also developed "non-flow-through" proton-exchange-membrane fuel cell stacks. The primary advantage of this technology set is the reduction of ancillary parts in the balance-of-plant--fewer pumps, separators and related components should result in fewer failure modes and hence a higher probability of achieving very reliable operation, and reduced parasitic power losses enable smaller reactant tanks and therefore systems with lower mass and volume. Key accomplishments include the fabrication and testing of several robust, small-scale nonflow-through fuel cell stacks that have demonstrated proof-of-concept. This report summarizes the project s goals, objectives, technical accomplishments, and risk assessments. A bibliography spanning the life of the project is also included.
Thermophysical properties of potential thermal energy storage materials for design of TES THERMIONIC systems for long duration space flights
This thesis developed a system-level optimization model of a regenerative fuel cell (RFC) system for long-duration, off-world energy storage applications. Prior RFC design studies have typically been limited to reduced parameter sets and simplified constraints due to computational limitations relative to the number of relevant degrees of freedom. As a result, important nonlinear interactions between subsystems have not been fully captured. This work began to address that gap by developing a higher-fidelity, nonlinear optimization framework that incorporates a broader set of design variables and coupled constraints, enabling a multidimensional model that captures the coupled behavior of RFC subsystems and demonstrates the feasibility of applying optimization to such systems. An expanded system-level optimization approach was established that captures interactions between electrochemical performance, structural requirements, and storage design. This enabled a more comprehensive evaluation of trade-offs than conventional formulations. The model integrates four coupled subsystems: a fuel cell, an electrolyzer, reactant gas, and high-pressure storage tanks, and was formulated to accommodate a wide range of mission parameters, including operational time and required output power. It incorporates constraints on available solar array power, reactant mass balance between production and consumption, and pressure-dependent storage requirements. To enable reliable convergence, the optimization problem was reformulated to reduce dimensionality and improve numerical stability, with subsystem models organized for efficient evaluation. Problem dimensionality was reduced by consolidating lower-level design variables into higher-level representative quantities, and subsystem behavior was evaluated within the optimization loop. A multi-start initialization strategy was employed to mitigate sensitivity to local minima and improve solution quality, while nonlinear relationships were solved using robust numerical methods. The results showed that convergence was achieved across a range of required output power values. Specific energy reached a maximum at a critical mission power level, where the electrolyzer power matched the available solar input and operated near its voltage and current density limits. Beyond this point, further increases in required power resulted in less mass-efficient operation, increasing total system mass and reducing overall performance. The developed model represents an advancement in RFC system-level optimization by enabling analysis of a broader and more tightly coupled design space than previous considerations. While convergence behavior and computational cost remain challenges, the methods introduced improve solvability and allow inclusion of additional design variables with minimal loss of physical fidelity. However, the numerical results should not be interpreted as definitive design recommendations, as the model includes simplifying assumptions and omits several higher-order effects. Future work should extend this framework by incorporating additional subsystems and loss mechanisms, such as thermal management, parasitic power consumption, and reactant losses, to improve fidelity and ensure more representative design conclusions.
The Thermal Energy Storage-1 (TES-1) is a flight experiment that flew on the Space Shuttle Columbia (STS-62), in March 1994, as part of the OAST-2 mission. TES-1 is the first experiment in a four experiment suite designed to provide data for understanding the long duration microgravity behavior of thermal energy storage fluoride salts that undergo repeated melting and freezing. Such data have never been obtained before and have direct application for the development of space-based solar dynamic (SD) power systems. These power systems will store solar energy in a thermal energy salt such as lithium fluoride or calcium fluoride. The stored energy is extracted during the shade portion of the orbit. This enables the solar dynamic power system to provide constant electrical power over the entire orbit. Analytical computer codes have been developed for predicting performance of a spaced-based solar dynamic power system. Experimental verification of the analytical predictions is needed prior to using the analytical results for future space power design applications. The four TES flight experiments will be used to obtain the needed experimental data. This paper will focus on the flight results from the first experiment, TES-1, in comparison to the predicted results from the Thermal Energy Storage Simulation (TESSIM) analytical computer code. The TES-1 conceptual development, hardware design, final development, and system verification testing were accomplished at the NASA lewis Research Center (LeRC). TES-1 was developed under the In-Space Technology Experiment Program (IN-STEP), which sponsors NASA, industry, and university flight experiments designed to enable and enhance space flight technology. The IN-STEP Program is sponsored by the Office of Space Access and Technology (OSAT).
Process results in long-duration sparks which allow leaner, cleaner combustion. Procedure is not limited by available energy-storage devices and can produce continuous spark of as long duration as desired for optimum engine operation and pollution reduction. System can be modified to operate on engines not using distributor points and can be used with conventional Kettering ignitions.
Thermal Energy Storage-2 (TES-2) is a flight experiment that flew on the Space Shuttle Endeavour (STS-72), in January 1996. TES-2 originally flew with TES-1 as part of the OAST-2 Hitchhiker payload on the Space Shuttle Columbia (STS-62) in early 1994. The two experiments, TES-1 and TES-2 were identical except for the fluoride salts to be characterized. TES-1 provided data on lithium fluoride (LiF), TES-2 provided data on a fluoride eutectic (LiF/CaF2). Each experiment was a complex autonomous payload in a Get-Away-Special payload canister. TES-1 operated flawlessly for 22 hr. Results were reported in a paper entitled, Effect of Microgravity on Materials Undergoing Melting and Freezing-The TES Experiment, by David Namkoong et al. A software failure in TES-2 caused its shutdown after 4 sec of operation. TES-1 and 2 were the first experiments in a four experiment suite designed to provide data for understanding the long duration microgravity behavior of thermal energy storage salts that undergo repeated melting and freezing. Such data have never been obtained before and have direct application for the development of space-based solar dynamic (SD) power systems. These power systems will store energy in a thermal energy salt such as lithium fluoride or a eutectic of lithium fluoride/calcium difluoride. The stored energy is extracted during the shade portion of the orbit. This enables the solar dynamic power system to provide constant electrical power over the entire orbit. Analytical computer codes were developed for predicting performance of a space-based solar dynamic power system. Experimental verification of the analytical predictions were needed prior to using the analytical results for future space power design applications. The four TES flight experiments were to be used to obtain the needed experimental data. This paper will address the flight results from the first and second experiments, TES-1 and 2, in comparison to the predicted results from the Thermal Energy Storage Simulation (TESSIM) analytical computer code. An analysis of the TES-2 data was conducted by Cleveland State University Professor, Mounir Ibrahim. TESSIM validation was based on two types of results; temperature history of various points on the containment vessel and TES material distribution within the vessel upon return from flight. The TESSIM prediction showed close comparison with the flight data. Distribution of the TES material within the vessel was obtained by a tomography imaging process. The frozen TES material was concentrated toward the colder end of the canister. The TESSIM prediction indicated a similar pattern. With agreement between TESSIM and the flight data, a computerized representation was produced to show the movement and behavior of the void during the entire melting and freezing cycles.
In the past, NASA has employed solar photovoltaic devices for long-duration missions. Thus, the Skylab system has operated with a silicon photovoltaic array and a nickel-cadmium electrochemical system energy storage system. Difficulties regarding the employment of such a system for the larger power requirements of the Space Station are related to a low orbit system efficiency and the large weight of the battery. For this reason the employment of a solar dynamic power system (SDPS) has been considered. The primary components of an SDPS include a concentrating mirror, a heat receiver, a thermal energy storage (TES) system, a thermodynamic heat engine, an alternator, and a heat rejection system. The heat-engine types under consideration are a Brayton cycle engine, an organic Rankine cycle engine, and a free-piston/linear-alternator Stirling cycle engine. Attention is given to a system description, TES integration concepts, and a TES technology assessment.
The present investigation reports a study of bubble generation under reduced gravity conditions, using both a co-flow and a cross-flow configuration. This study may be used in the conceptual design of a space-based thermal management system. Ensuing two-phase flow void fraction can be accurately monitored using a single nozzle gas injection system within a continuous liquid flow conduit, as utilized in the present investigation. Accurate monitoring of void fraction leads to precise control of heat and mass transfer coefficients related to a thermal management system; hence providing an efficient and highly effective means of removing heat aboard spacecraft or space stations. Our experiments are performed in parabolic flight aboard the modified DC-9 Reduced Gravity Research Aircraft at NASA Lewis Research Center, using an air-water system. For the purpose of bubble dispersion in a flowing liquid, we use both a co-flow and a cross-flow configuration. In the co-flow geometry, air is introduced through a nozzle in the same direction with the liquid flow. On the other hand, in the cross-flow configuration, air is injected perpendicular to the direction of water flow, via a nozzle protruding inside the two-phase flow conduit. Three different flow conduit (pipe) diameters are used, namely, 1.27 cm, 1.9 cm and 2.54 cm. Two different ratios of nozzle to pipe diameter (D(sub N))sup * are considered, namely (D(sub N))sup * = 0.1 and 0.2, while superficial liquid velocities are varied from 8 to 70 cm/s depending on flow conduit diameter. It is experimentally observed that by holding all other flow conditions and geometry constant, generated bubbles decrease in size with increase in superficial liquid velocity. Detached bubble diameter is shown to increase with air injection nozzle diameter. Likewise, generated bubbles grow in size with increasing pipe diameter. Along the same lines, it is shown that bubble frequency of formation increases and hence the time to detachment of a forming bubble decreases, as the superficial liquid velocity is in-creased. Furthermore, it is shown that the void fraction of the resulting two-phase flow increases with volumetric gas flow rate Q(sub d), pipe diameter and gas injection nozzle diameter, while they decrease with surrounding liquid flow. The important role played by flowing liquid in detaching bubbles in a reduced gravity environment is thus emphasized. We observe that the void fraction can be accurately controlled by using single nozzle gas injection, rather than by employing multiple port injection, since the later system gives rise to unpredictable coalescence of adjacent bubbles. It is of interest to note that empirical bubble size and corresponding void fraction are somewhat smaller for the co-flow geometry than the cross-flow configuration at similar flow conditions with similar pipe and nozzle diameters. In order to supplement the empirical data, a theoretical model is employed to study single bubble generation in the dynamic (Q(sub d) = 1 - 1000 cu cm/s) and bubbly flow regime within the framework of the co-flow configuration. This theoretical model is based on an overall force balance acting on the bubble during the two stages of generation, namely the expansion and the detachment stage. Two sets of forces, one aiding and the other inhibiting bubble detachment are identified. Under conditions of reduced gravity, gas momentum flux enhances, while the surface tension force at the air injection nozzle tip inhibits bubble detachment. In parallel, liquid drag and inertia can act as both attaching and detaching forces, depending on the relative velocity of the bubble with respect to the surrounding liquid. Predictions of the theoretical model compare well with our experimental results. However, at higher superficial liquid velocities, as the bubble loses its spherical form, empirical bubble size no longer matches the theoretical predictions. In summary, we have developed a combined experimental and theoretical work, which describes the complex process of bubble generation and resulting two-phase flow in a microgravity environment. Results of the present study can be used in a wide range of space-based applications, such as thermal energy and power generation, propulsion, cryogenic storage and long duration life support systems, necessary for programs such as NASA's Human Exploration for the Development of Space (HEDS).
Responding to a request from the Air Force, NASA Lewis Research Center engineers designed a combination pressure control and propellant delivery system based on thermodynamic vent system (TVS) technology. The Air Force is designing a new type of orbit transfer vehicle that uses energy from sunlight to both propel and power the vehicle. Because this vehicle uses propellant at a substantially slower rate than higher-energy rockets, it needed the Lewis-developed TVS technology for long-duration storage of cryogen propellants. Lewis engineers, in conjunction with industry partners, showed how this TVS technology could also be used to deliver propellant to the thruster. The Air Force has now begun the ground test demonstration phase. After successful completion of ground testing, the Air Force plans to use this technology in a space flight as early as 1999.
Autonomous Underwater Vehicles (AUV s) have received increasing attention in recent years as military and commercial users look for means to maintain a mobile and persistent presence in the undersea world. Compact, neutrally buoyant power systems are needed for both small and large vehicles. Batteries are usually employed in these applications, but the energy density and therefore the mission duration are limited with current battery technology. At a certain energy or mission duration requirement, other means to get long duration power become feasible. For example, above 10 kW-hrs liquid oxygen and hydrogen have better specific energy than batteries and are preferable for energy storage as long as a compact system of about 100 W/liter is achievable to convert the chemical energy in these reactants into power. Other reactant forms are possible, such as high pressure gas, chemical hydrides or oxygen carriers, but it is essential that the power system be small and light weight. Recent fuel cell work, primarily focused on NASA applications, has developed power systems that can meet this target power density. Passive flow-through systems, using ejector driven reactant (EDR) flow, integrated into a compact balance of plant have been developed. These systems are thermally and functionally integrated in much the same way as are automotive, air breathing fuel cell systems. These systems fit into the small volumes required for AUV and future NASA applications. Designs have been developed for both a 21" diameter and a larger diameter (LD) AUV. These fuel cell systems occupy a very small portion of the overall energy system, allowing most of the system volume to be used for the reactants. The fuel cell systems have been optimized to use reactants efficiently with high stack efficiency and low parasitic losses. The resulting compact, highly efficient fuel cell system provides exceptional reactant utilization and energy density. Key design variables and supporting test data are presented. Future development activities are described.
Solar powered aircraft are of interest for exploring both Mars and Venus. The thin atmosphere of Mars presents a difficult environment for flying. It is clear that a new approach is needed. By making a totally solar airplane, we can eliminate many of the heavy components, and make an airplane that can fly without fuel. Using high efficiency solar cells, we can succeed with an airplane design that can fly for up to 6 hours in near-equatorial regions of Mars (4 hours of level flight, plus two hours of slow descent), and potentially fly for many days in the polar regions. By designing an airplane for a single day flight. In particular, this change means that we no longer have to cope with the weight of the energy storage system that made previous solar powered airplanes for Mars impractical). The new airplane concept is designed to fly only under the optimal conditions: near equatorial flight, at the subsolar point, near noon. We baseline an 8 kg airplane, with 2 kg margin. Science instruments will be selected with the primary criterion of low mass. Solar-powered aircraft are also quite interesting for the exploration of Venus. Venus provides several advantages for flying a solar-powered aircraft. At the top of the cloud level, the solar intensity is comparable to or greater than terrestrial solar intensities. The atmospheric pressure makes flight much easier than on planets such as Mars. The atmospheric pressure on Venus is presented. From an altitude of approximately 45 km (pressure = 2 bar), to approximately 60 km (pressure = 0.2 bar), terrestrial airplane experience can be easily applied to a Venus airplane design. At these flight altitudes, the temperature varies from 80 C at 45 km, decreasing to -35 C at 60 km. Also, the slow rotation of Venus allows an airplane to be designed for flight within continuous sunlight, eliminating the need for energy storage for nighttime flight. These factors make Venus a prime choice for a long-duration solar-powered aircraft. Fleets of solar-powered aircraft could provide an architecture for efficient and low-cost comprehensive coverage for a variety of scientific missions. Exploratory planetary mapping and atmospheric sampling can lead to a greater understanding of the greenhouse effect not only on Venus but on Earth as well.
This paper presents illumination analyses using the latest Earth-based radar digital elevation model (DEM) of the lunar south pole and an independently developed analytical tool. These results enable the optimum sizing of solar/energy storage lunar surface power systems since they quantify the timing and durations of illuminated and shadowed periods. Filtering and manual editing of the DEM based on comparisons with independent imagery were performed and a reduced resolution version of the DEM was produced to reduce the analysis time. A comparison of the DEM with lunar limb imagery was performed in order to validate the absolute heights over the polar latitude range, the accuracy of which affects the impact of long range, shadow-casting terrain. Average illumination and energy storage duration maps of the south pole region are provided for the worst and best case lunar day using the reduced resolution DEM. Average illumination fractions and energy storage durations are presented for candidate low energy storage duration south pole sites. The best site identified using the reduced resolution DEM required a 62 hr energy storage duration using a fast recharge power system. Solar and horizon terrain elevations as well as illumination fraction profiles are presented for the best identified site and the data for both the reduced resolution and high resolution DEMs compared. High resolution maps for three low energy storage duration areas are presented showing energy storage duration for the worst case lunar day, surface height, and maximum absolute surface slope.
NASA needs energy storage for lunar applications where night lasts up to 354 hours. Reversible fuel cell systems are potentially well-suited for long-duration storage but must have high reliability to last the 4-year maintenance cycle. Moving parts (compressors and blowers) are the primary limitation for high reliability fuel cell systems. Further, H2 and O2 have numerous ISRU applications, including propellant, life support, and chemical processes.
The Gandalf Staff is a mobile tool designed to be a flexible device supporting crewed and uncrewed operations on the lunar surface. The core of the device is a 24v battery with communications and data storage systems. Initial optional components supporting crewed Extra-Vehicular Activity (EVA) include a LiDAR and 360˚ camera. These provide 3D mapping of the traverse for documentation, and to aid future planning. The mapping also creates outreach opportunities for the public to “stand beside” the astronaut in Virtual Reality (VR). The staff provides external lighting for field site illumination in the south polar region low sun angle environment. Navigation instruments for crew position determination with Lunar Search and Rescue (LunaSAR) are also included. The staff itself can be used as a walking aid or as a splint for Incapacitated Crew Rescue (ICR). As a stand-alone device, the staff operates as a long duration untended science platform collecting environmental data and sending it to a lunar base station. The stand-alone mode requires connection to an auxiliary power source (e.g. solar array) and energy storage system (e.g. battery), so it could become an electrical recharging station. To make rapid progress in the 1st year, and also to demonstrate innovative project management techniques, NASA guided a private industry partner, T STAR, in leading Capstone Engineering student teams at Texas A&M University (TAMU) for proof-of-concept development and testing. These teams developed the power system and demonstrated successful integration of LiDAR, WiFi communications, and external lighting subsystems. Another industry team at Jacobs Technology prototyped a tripod to hold the staff upright. For the 2nd year (FY’22), NASA will again collaborate with partners to prototype enhanced power and lighting concepts. Year 2 will also add new capability for LunaSAR and geophysical science instrumentation using a heat probe. The heat probe is based upon Apollo heritage but modified to measure subsurface volatile ice regimes at the Artemis landing site. Components of the Gandalf Staff can be developed, tested, and deployed independently, or on the integrated staff, rovers, or utility trailers. The project supports crew safety, lunar sample curation, mission science, and public outreach goals of NASA. PLAIN TEST SUMMARY: Gandalf Staff is a 24v battery powered mobile tool for the lunar surface supporting crewed geologic field site exploration, or as a stand-alone science platform. As a tool assisting astronauts conducting field geology, the Gandalf Staff provides external lighting to illuminate shadowed regions on the surface. It also documents the process of collecting rocks and dust samples using a LiDAR (laser range instrument) and cameras. The staff provides a beacon for emergency location of astronauts and augments communications when the astronauts are blocked by large boulders. As a standalone science platform, the Gandalf Staff provides a power system for instruments and sensors to measure the lunar environment over long periods of time. The staff gathers data and sends the results to a lunar base station for analysis.
Achieving NASAs aggressive fuel burn and emission reduction for N-plus-3 aircraft will require hybrid electric propulsion system in which electric motors driven by either power generated from turbine or energy storage system will power the fan for propulsion. Motors designed for hybrid electric aircraft are expected to operate at medium to high voltages over long durations in a high altitude service environment. Such conditions have driven research toward the development of wire insulation with improved mechanical strength, thermal stability and increased breakdown voltage. The silicone class of materials has been considered for electric wire insulation due to its inherent thermal stability, dielectric strength and mechanical integrity. This paper evaluates the dependence of these properties on the cure conditions of a polydimethyl-siloxane (PDMS) elastomer; where both cure temperature and base-to-catalyst ratio were varied. The PDMS elastomer was evaluated as a bulk material and an impregnation matrix within a lightweight glass veil support. The E-glass support was selected for mechanical stiffness and dielectric strength. This work has shown a correlation between cure conditions and material physical properties. Tensile strength increased with cure temperature whereas breakdown voltage tended to be independent of process variations. The results will be used to direct material formulation based on specific insulation requirements.
A solar-powered airplane is proposed to explore the atmospheric environment of Venus. Venus has several advantages for a solar airplane. At the top of the cloud level, the solar intensity is comparable to or greater than terrestrial solar intensities. The Earthlike atmospheric pressure means that the power required for flight is lower for Venus than that of Mars, and the slow rotation of Venus allows an airplane to be designed for continuous sunlight, with no energy storage needed for night-time flight. These factors mean that Venus is perhaps the easiest planet in the solar system for flight of a long-duration solar airplane.