Engineering topics

Smith, James A.

Publications and source records attributed to Smith, James A..

At least 19 records

DOE OSTI2024

Application of printed strain gauges in prototypical nuclear reactor conditions

This report discusses the current development and testing of additively manufactured temperature sensors and resistive/ capacitive strain gauges. This has potential to improve the sensor design and manufacturing techniques to meet the requirements of in-pile monitoring of mechanical properties and structural health of materials and specimens in current and advanced nuclear test reactors (i.e., in terms of environment conditions, sample geometry, and materials compatibility). The developmental additively manufactured strain gauges are exposed to separate effects testing (i.e., mechanical strain (up to 1000 µe), high temperature (up to 700 °C)) to determine environmental factors that affect the performance of the strain gauge. The robustness and integrity of a printed strain gauge layer exposed to a molten salt environment for up to 500 hours was evaluated, with the goal of assessing material compatibility of printed strain sensors for instrumented surveillance test articles in molten salt reactors. In addition, sensor qualification methodologies are further developed for determining the reliability and robustness at the interface of the additively manufactured strain gauge materials.

36 - MATERIALS SCIENCE↗

DOE OSTI2024

Robustness and printed sensor qualification

A limiting factor of additive manufactured (AM) sensors for in-pile applications is the development of appropriate interconnection and packaging strategies that can maintain reliable performance in extreme environments. Failure mechanisms in these harsh conditions could include, but not limited to, materials interaction (i.e., intermetallic formation) and coefficient of thermal expansion (CTE) mismatch between the individual components of the sensors. To mitigate premature failure and enable the successful sustained operation of AM sensors, non-destructive qualification tests are used as an intermediate process control step used for verifying robustness and reliability of the sensor before they are deployed. A materials system of interest is the use of barium strontium titanium oxide (BST) films on stainless steel 316L (SS316L) substrate. Due to BST’s high dielectric constant and tunable dielectric properties, there is an interest for its application as an insulation/encapsulation layer for capacitive strain gauges when printed on structural materials. Previous work on the BST/SS316L material system, however, showed that the BST cracks when exposed to temperatures up to 600 °C due to CTE mismatch between the printed BST film and the metallic substrate. When comparing different fabrication techniques, less surface cracking was observed in the samples that deposited thinner (i.e., 2-20 μm) than samples that were thicker (i.e., 135 µm – 300 µm). The objective of this report is to establish a qualification process that will determine and address any challenges (i.e., mechanical failure of thick prints) of the AM sensor prior to its application in experimental tests. To demonstrate the qualification process in this report, laser spallation and uniaxial tensile tests using dynamic and quasi-static loading, respectively, will be discussed.

36 - MATERIALS SCIENCE↗

DOE OSTI2023

Recursive Use of the Short-Time Fast Fourier Transform for Signature Analysis in Continuous Processes

Although a nuclear reactor is a hostile environment for sensing and electrical communications, the reactor core is amenable to acoustic communication. An acoustic measurement infrastructure (AMI) has been installed in the Advanced Test Reactor (ATR) to record acoustic signals that can capture its different operating regimes. AMI uses coolant pumps as continuous signal sources, coolant and structural components as transmission lines, and accelerometers to capture system motion. A recursive signal processing technique based on the short-time fast Fourier transform (STFFT) for continuous processes provides unique signatures for diagnostic and prognostic analyses from the system motion data. Here this article presents a recursive STFFT methodology that processes acoustic signals from continuous industrial processes. The article first discusses the initial STFFT use with simulated data to elucidate the basic principles necessary to understand and interpret the STFFT results from actual pump vibration data. Each repetitive use of the STFFT on pump vibration data using the results from the prior STFFT processing will generate additional complimentary time-frequency-based signatures. These signatures are generated by the coolant pumps operating under different process conditions. After each use of the STFFT, the resulting signatures provide exemplary examples of the diversity and intuitive nature of recursively using the STFFT. This article focuses on recursively using the STFFT to provide numerous complimentary and diverse signatures that will ultimately be inputs for machine learning algorithms that provide predictive data analytics. The intuitive nature of the information and signatures from recursive STFFT processing will also bring intuitive interpretation capabilities to machine learning and predictive data analytic techniques.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2023

Corroborating Channel Gap Probe Measurements with an Optical Profiler

As nuclear fuel plates get irradiated, the fuel plate thickness changes. How the fuel plate changes with irradiation is a significant parameter that is important to predict fuel performance in new fuel systems. The channel gap probe is used to indirectly infer changes in fuel plate thicknesses by measuring the gaps between the fuel plates contained within capsules after each irradiation cycle. Independent measures should be used to corroborate salient measurements such as changes in fuel thickness which help ascertain fuel performance. The use of traditional metrological tools to validate channel gap probe measurements are not practical due to the capsule geometry. The accuracy of the channel gap probe inserted within a capsule has not been verified. Since there is no “gold” standard measurement to verify CGP measurements, an optical profilometer has been used to corroborate the CGP measurements. The optical profilometer has been able to corroborate the capsules channel gaps to within 0.04 mm for both ends of the capsule. The optical profiler is also able to measure plate thickness that matched micrometer measurements to within 0.025 mm. In conclusion, the profilometer corroborated the CGP measurements but a discrepancy was found at one end of the capsule for the Inside Capsule Width from the profilometer when compared to a caliper measurement.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2022

Sensing units including a radio-frequency sensor, and related systems, devices, and methods

Systems, devices, and methods related to generating and/or transmitting sensor measurement data are described. A device may include a first conductive pad positioned on a first surface of a substrate. The device may also include a second conductive pad positioned on a second, opposite surface of the substrate. Further, the device may include an inductive coil coupled between the first electrical pad and the second electrical pad. Also, the device may include a third conductive pad positioned on a third surface of the substrate and configured to couple to a sensor. The device may include a fourth conductive pad positioned on a fourth surface of the substrate and configured to couple to the sensor. The device may be configured to wirelessly transmit a signal.

Smith, James A.↗

DOE OSTI2022

Data Architecture and Analytics Requirements for Artificial Intelligence and Machine Learning Applications to Achieve Condition-Based Maintenance

This report identified some of the important requirements that needs to be taken into consideration as part of the data evolution for the CBM application of a CWS in a NPP. In the data evolution process, the information is converted into insight leading into actions using advancements in AI/ML technologies. A notion of RESET AI: design, development, deployment, and operation principals are introduced to lifecycle of AI technologies. Towards the end of the report, we discussed how this CBM can be realized in a SDE. As path forward, this report lays the foundation for developing a more detailed industry guidance supporting data evolution for other plant applications like operations and plant support. These would be developed as part of ongoing research in the fiscal year 2023.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2022

Development of Quality Control Methods for Robust and Reliable Sensor Design

The successful adoption of additive manufacturing for the rapid prototyping of printed sensors requires the establishment of quantifiable metrics that can interrogate device performance. One measure of performance is the adhesion strength between the substrate and sensor interface, which is critical since the strength of this interface can dictate the accuracy and reliability of the printed sensor. In this work, a non-contact laser-induced spallation technique was used to quantify the adhesion of silver prints on an aluminum alloy substrate. The laser-based method was compared to a standardized pull-off adhesion test, which provided baseline measurements of adhesion strength. The sintering conditions were shown to play an important role in the film-substrate adhesion strength, as well as the cohesion and ductility of the film itself. The methods and results described in this work supports the establishment of process control steps that are necessary for verifying the reliability of printed devices prior to its deployment in critical experiments.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Predictive Data Analytics Framework Using Advanced Test Reactor Acoustic Data

Although a nuclear reactor is a hostile environment for sensing and electrical communications, the reactor core is amenable to acoustic communication. An acoustic measurement infrastructure (AMI) has been installed at the Advanced Test Reactor (ATR) nozzle trench area to record acoustic signals that has the ability to capture different operating regime of the reactor. This AMI includes ATR in-pile structural components, coolant, acoustic receivers, primary coolant pumps (PCP) as signal sources, a data acquisition system, and signal-processing algorithms, enabling real-time. This report will discusses development of recursive Fast Fourier Transform approach to process in real-time acoustic signals, application of short time Fast Fourier Transform to the ATR brush data to understand the vibration level and to develop spectrograms for different primary coolant pump combinations. The combination of primary coolant pumps for normal and power axial locator mechanism of ATR are different and generates different signatures. These acoustic signatures were used to develop machine learning approaches to automatically classify different operating regimes. This lay the foundation for predictive analytic framework that can be leverage by ATR to optimize their operation and maintenance. The path forward involves continued engagement with ATR and expanded implementation of AMI and predictive framework at ATR and other facilities within INL and at other experimental reactors.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2020

Wireless Sensing and Communication Capability from In-Core to a Monitoring Center

Significant cost savings can be made if electrical cables can be replaced by wireless technology in current Nuclear Power Plants (NPP) and in advance reactor designs. Wireless technology can also provide in-core opportunities by significantly reducing the number of penetrations in the pressure vessel, cost and complexity of sensor installation and by increasing the efficiency of current and advanced reactors. Unlike other deployment scenarios for an industrial environment, operators need to have centralized control over all the networks. Centralized control will reduce implementation costs, provide single point control and enable monitoring of network devices, improve security, and enhance connectivity. Micro-sensors that can simultaneously monitor temperature and pressure within a fuel rod inside nuclear reactors will enable preventative actions during abnormal operating conditions. This ability could avert accidents and enable the expedient development of accident tolerant fuels. A novel micro-sensor suite (~ mm) to simultaneously measure multiple parameters such as temperature, strain, pressure, and neutron/gamma flux inside a fuel rod is being developed for use in reactors. The necessary communication architecture is also being developed to transmit measurement signals from the core to the plant's data cloud or control room. A three three-tier strategy has been developed to support wireless transmission of in-core measurements to the control room or to a secure cloud platform for control, analytics, and decision-making purposes. 1. In-core: data signal from in-core to outside of the pressure vessel within the containment building 2. Containment building: data signal from inside to the outside of the containment building and into the balance of the plant network 3. Balance of the plant network: information transmitted to the data cloud and control room This plan presents a wireless sensing and communication system for use within a reactor core and elsewhere. The communication technology is advantageous to compensate for network equipment failures and adverse data transmission conditions. Wireless technology will significantly increase the resiliency of the plants network system. The wireless system naturally provides multiple transmission path capability and data redundancy.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2020

Non-contact velocity measurement instruments and systems, and related methods

Methods for calibration of non-contact velocity measurements and systems for implementing the same are described. Generally, the method comprises inducing a shock wave into a sample at a stress intensity that varies across the sample's elastic limit, which corresponds to the elastic-plastic state transition of the sample. That transition state may be at the sample's Hugoniot elastic limit. The velocity of the sample is measured using a non-contact velocity measurement instrument such as a velocimeter. The measurement may be compared to a predicted velocity or a velocity measurement made by another system to determine calibration parameters.

47 OTHER INSTRUMENTATION↗

DOE OSTI2019

Technology-Enabled Risk-Informed Maintenance Strategy to Minimize Operation and Maintenance Costs

The domestic fleet of nuclear power plants (NPPs) is facing a unique economic sustainability challenge in today’s energy market due to high total operating costs. One of the major contributors to the total operating cost of an NPP is the operations and maintenance (O&M) budget, which includes labor-intense preventive maintenance (PM) programs. PM programs involve manually performing inspection, calibration, testing, and maintenance of plant assets at periodic frequencies, as well as time-based replacement of assets, irrespective of individual asset condition. This approach, combined with the push to achieve high capacity factors, has resulted in a labor-centric business model. It is time to transition from this labor-centric business model to a technology-centric business model that will enable an optimal maintenance strategy by eliminating unnecessary costs associated with time-based PM activities. To enable this transition, the commercial nuclear industries are utilizing and developing reliable methodologies, based on available state of the art technologies, which facilitate assessing equipment condition and the dynamic risk of failure. The U.S. Department of Energy’s Idaho National Laboratory (INL) under the Light Water Reactor Sustainability (LWRS) Program is partnering with PKMJ Technical Services and Public Service Enterprise Group (PSEG) Nuclear, LLC to develop and demonstrate a deployable risk-informed predictive maintenance strategy to eliminate unnecessary O&M costs for an identified plant system, laying the foundation for scale-up to the entire plant. Recently developed technologies such as advanced wireless and wired sensors, data analytics, and risk assessment methodologies will support this transition. The technology-centric O&M model will result in significant automation and lay the foundation for real-time condition assessment of plant assets, thus enabling condition-based maintenance and enhancing plant safety, reliability, and economics of operation.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2019

Thermoacoustic enhancements for nuclear fuel rods

A nuclear thermoacoustic device includes a housing defining an interior chamber and a portion of nuclear fuel disposed in the interior chamber. A stack is disposed in the interior chamber and has a hot end and a cold end. The stack is spaced from the portion of nuclear fuel with the hot end directed toward the portion of nuclear fuel. The stack and portion of nuclear fuel are positioned such that an acoustic standing wave is produced in the interior chamber. A frequency of the acoustic standing wave depends on a temperature in the interior chamber.

Garrett, Steven L.↗

DOE OSTI2018

Channel Gap Probe EMPIrE Report

EMPIrE aims to provide data for the "comprehension phase" of the European Low Enriched Uranium (LEU ) U-Mo Fuel Development program for the conversion of European civilian research reactors. The majority of the fuel performance data will be obtained during post-irradiation examinations (PIE) of the fuel. The primary EMPIrE fuel specimen design is based on uranium-molybdenum (U-Mo) alloy particles dispersed in an aluminum matrix clad in the European alloy AG3NE and in the form of mini-plate sized specimens (1" x 4" plates). Secondary EMPIrE specimens include U Mo monolithic fuel clad in European alloy AlFeNi. The experiment is designed in such a way that U-Mo samples achieve three distinct end-of-life burnup groupings. Irradiation has taken place at ATR (Advance Treatment Reactor). The fuel plates are contained in fuel capsules holding four plates each, with 2 plates at 2 levels. Once the capsules with the plates are irradiated, they have to be inspected during the outage in-between cycles. The capsules need to have visual inspection performed and channel gap widths measured prior to reinsertion. These inspections are to ensure that the plates have not deformed significantly. Obstruction of the coolant channels and restriction of the coolant flow are less of a concern in EMPIrE testing as the channels were made intentionally wide. The Channel Gap Probe (CGP) has been developed to measure channel gap widths, which serves as indirect measures of the fuel plate performance and deformation in the course of irradiation which enables the evaluation of the risk from continuing irradiation prior to reinsertion of the plates in reactor.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2018

Vibro-acoustic Testing for Microstructure Characterization and Metrology: Technology Commercialization Fund—Fiscal Year 2017

There is a need in nuclear reactors to inspect irradiated materials and structures. A portable scanning infrastructure for a material characterization technique called vibro acoustography (VA) is being developed by the Idaho National laboratory for nuclear applications to characterize fuel, cladding materials, and structures. The proposed VA technology is based on ultrasound and acoustic waves; however, it provides information beyond what is available from the traditional ultrasound techniques and can expand the knowledge on nuclear material characterization and microstructure evolution. VA technique has several advantages over traditional characterization techniques. VA is a non-contact submersion technique that is inherently wireless transmission and reception (from the ultrasonic transmitter to the acoustic receiver). The transmission medium can be most liquids used for reactor cooling such as water and sodium. For nuclear in-pile applications, the Ultrasonic Transducer (UT) will need to have a line of sight location that is within lower radiation flux zones. Multiple UT sources can be frequency multiplexed to allow a single hydrophone receiver to monitor several locations. The reactor structure can also be an integral part of the transmission system acting as waveguides to deliver the acoustic signal to an acoustic receiver. Because of the long wavelength of the acoustic signal, the acoustic receiver does not have to be line of sight with respect to the component under test. The focusing and generation of the acoustic beat frequency from two ultrasonic waves allows for the potential to ultrasonically image complex shapes. These features will significantly reduce experiment complexity, installation times and cost while being safe and easy to use.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS2017

Laser Spiderweb Sensor Used with Portable Handheld Devices

A portable spectrometer, including a smart phone case storing a portable spectrometer, wherein the portable spectrometer includes a cavity; a source for emitting electromagnetic radiation that is directed on a sample in the cavity, wherein the electromagnetic radiation is reflected within the cavity to form multiple passes of the electromagnetic radiation through the sample; a detector for detecting the electromagnetic radiation after the electromagnetic radiation has made the multiple passes through the sample in the cavity, the detector outputting a signal in response to the detecting; and a device for communicating the signal to a smart phone, wherein the smart phone executes an application that performs a spectral analysis of the signal.

Scott, David C.↗

DOE OSTI2017

Temperature Sensitivity Study of Eddy Current and Digital Gauge Probes for Nuclear Fuel Rod Oxide Measurement

Temperature Sensitivity Study of Eddy Current and Digital Gauge Probes for Nuclear Fuel Rod Oxide Measurement Faith R. Beck, Department of Mechanical Engineering, Penn State University, State College, PA R. Paul Lind and James A. Smith, Idaho National Laboratory, Idaho Falls, ID Novel fuels are part of the nationwide effort to reduce the enrichment of Uranium for energy production. Performance of such fuels is determined by irradiating their surfaces. To test irradiated samples, the machinery must operate remotely. The plate checker used in this experiment at Idaho National Lab (INL) performs non-destructive testing on fuel rod and plate geometries with two different types of sensors: eddy current and digital thickness gauges. The sensors measure oxide growth and total sample thickness on research fuels, respectively. Sensor measurement accuracy is crucial because even 10 microns of error is significant when determining the viability of an experimental fuel. One parameter known to affect the eddy current and thickness gauge sensors is temperature. Since both sensor accuracies depend on the ambient temperature of the system, the plate checker has been characterized for these sensitivities. The eddy current probes were tested previously in a non-radioactive environment and are noted to have sensitivity to temperature. The manufacturer of the digital gauge probes has noted a rather large coefficient of thermal expansion for their linear scale. It should also be noted that the accuracy of the digital gauge probes are specified at 20°C, which is approximately 7°C cooler than the average hot-cell temperature. In this work, the effect of temperature on the eddy current and digital gauge probes is studied, and thickness measurements are given as empirical functions of temperature. Acknowledgement: This work was supported by the INL and the DOE office of NNSA (National Nuclear Safety Administration).

36 MATERIALS SCIENCE↗

DOE OSTI2017

Further Investigation of Surface Velocity Measurements for Material Characterization in Laser Shockwave Experiments

Further investigation of surface velocity measurements for material characterization in laser shockwave experiments James A. Smith, Jeffrey M. Lacy, Clark L. Scott, Bradley C. Benefiel Idaho National Laboratory, Idaho Falls ID Daniel Levesque, Jean-Pierre Monchalin and Martin Lord, National Research Council Canada, Boucherville, QC, Canada ---As part of the US High Performance Research Reactor program, a laser shockwave system is being developed by the Idaho National Laboratory (INL) to characterize interface strength in innovative plate fuel for research reactors around the world. The INL has been working with National Research Council Canada (NRC) on this project for the last five years. One of the concerns is the difficulty of calibrating and standardizing the laser shock technique. The generation of a stress wave by the laser impinging on the plate surface is dependent on the surface preparation, temporal and spatial power distribution of the laser spot, and material properties of the plate. Thus the resulting back surface velocity used to measure the time-varying stress field within the plate is difficult to reproduce across different measurement systems. ---A recent analytical study and testing support the use of the Hugoniot Elastic Limit (HEL) in materials as a robust and simple benchmark to compare stresses generated by different laser shock systems [1]. Using a non-contact laser velocimeter based on a solid Fabry-Perot etalon, the systems at NRC and INL showed that the velocity reached at the HEL is consistent, independent of the laser power used. In this work, the laser velocimeter of the NRC system is tested against a fast rotating wheel to verify accuracy and determine best operating conditions. A round robin test between the two laser shock systems on plates of different Al alloys is presented that shows the correct classification of the Al alloys based on the HEL as well as determining the bias between the systems. Also the effects of some setup parameters on other characteristics of the surface velocity and corresponding stress wave are discussed. 1. J.A. Smith, J.M. Lacy, D. Levesque, J.-P. Monchalin and M. Lord, "Use of the Hugoniot elastic limit in laser shockwave experiments to relate velocity measurements, 42nd Annual Review of Progress in Quantitative Nondestructive Evaluation, AIP Conf. Proc. 1706, pp. 080005-1-080005-10, 2016.

36 MATERIALS SCIENCE↗

DOE OSTI2017

Portable Vibro-acoustic Testing System for In Situ Microstructure Characterization and Metrology

Portable Vibro-acoustic Testing System for In situ Microstructure Characterization and Metrology James A. Smith, Corrie I. Nichol Idaho National Laboratory, Idaho Falls ID Mostafa Fatemi, Mayo Clinic, Rochester MN There is a need in research reactors like the INL to inspect irradiated materials and structures. The goal of this work is to develop a portable scanning infrastructure for a material characterization technique called vibro-acoustography (VA) that has been developed by INL [1] for nuclear applications to characterize fuel, cladding materials, and structures. The proposed VA technology is based on ultrasound and acoustic waves; however, it provides information beyond what is available from the traditional ultrasound techniques and can expand the knowledge on nuclear material characterization and microstructure evolution. VA is a three-dimensional (3D) imaging modality based on ultrasound-stimulated acoustic emission. VA uses the force caused by the beating of two frequencies to generate an acoustic emission signal. Due to absorption or reflection, the energy density in the object at an acoustic focal point changes to produce a “radiation force.” This force locally vibrates the object, which results in an acoustic field that depends on the characteristics of the object at that point. This acoustic field is detected for every point in the object; the resulting data is used to make an image of the object’s mechanical properties. This technology is fundamentally different from traditional ultrasound imaging. More specifically, VA is: (a) based on the “radiation force,” a nonlinear phenomenon in sound propagation, and (b) sensitive to both high and low frequency dynamic responses of the object. The combination of these two response types provides information about characteristics of the object beyond what is possible by traditional ultrasound imaging. High spatial resolution is achieved, since the radiation force is localized to the focal point of the ultrasound beam. Low-frequency information, which is a representative of structural characteristics, is gained through the radiation force mechanism at a low (beat) frequency. This paper will report on the development of a portable scanning that can be set up to characterize materials and component in open water reactors and canals in situ. We will show some initial laboratory results of images generated by vibro-acoustics of surrogate fuel plates and graphite structures and discus the design of the portable system. 1. Smith, J. A., and Kunerth, D. C., “Vibro-acoustic Sensors for Materials Characterization and Related Methods and Systems,” Patent Application 13226280, 09/06/2011.

36 MATERIALS SCIENCE↗