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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
DOE OSTI2025

Evaluation and Development of Phase Array Ultrasonic Testing (PAUT) System for Additively Manufactured Parts

This research focuses on the application of advanced ultrasonic testing techniques developed by The Phased Array Company (TPAC) for inspecting defects in additive manufacturing (AM) parts. Traditionally, X-ray computed tomography is the standard for inspecting AM components. Although, the long inspection and analysis time, along with relatively high cost make implementation difficult. Thus, an alternative nondestructive evaluation (NDE) approach is necessary to support quality assurance efforts within the field of AM. TPAC is recognized as a leader in ultrasonic testing innovation, deploying sophisticated algorithms such as Total Focusing Method (TFM) and Phased Wave Imaging (PWI) for ultrasonic data processing and interpretation. This work will explore how the TFM and PWI algorithms can assist defect detection within polymer AM parts. The AM field is seeking novel NDE methods to provide support within quality control and assurance efforts. Advanced ultrasonics inspection have the potential to fulfill this need.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2025

Evaluation and Development of Phase Array Ultrasonic Testing (PAUT) System for Additively Manufactured Parts

This research focuses on the application of advanced ultrasonic testing techniques developed by The Phased Array Company (TPAC) for inspecting defects in additive manufacturing (AM) parts. Traditionally, X-ray computed tomography is the standard for inspecting AM components. Although, the long inspection and analysis time, along with relatively high cost make implementation difficult. Thus, an alternative nondestructive evaluation (NDE) approach is necessary to support quality assurance efforts within the field of AM. TPAC is recognized as a leader in ultrasonic testing innovation, deploying sophisticated algorithms such as Total Focusing Method (TFM) and Phased Wave Imaging (PWI) for ultrasonic data processing and interpretation. This work will explore how the TFM and PWI algorithms can assist defect detection within polymer AM parts. The AM field is seeking novel NDE methods to provide support within quality control and assurance efforts. Advanced ultrasonics inspection have the potential to fulfill this need.

36 MATERIALS SCIENCE↗
DOE OSTI2020

PV Fleet Performance Data Initiative (March 2020 Methodology Report)

Data for thousands of systems by multiple sources were transmitted to NREL for evaluation. Initial automated data quality assurance (QA) checks identified hundreds of systems (QA Tier 1) with high-quality meteorological and AC production data and hundreds of QA Tier 2 systems with adequate data quality. A standard RdTools analysis was conducted for these systems, evaluating performance loss on an annualized basis. To date with the systems evaluated so far, we find a median performance loss rate (aka Rd or degradation rates) for the entire fleet of -0.72%/year based on individual inverter data, which is in line with historical degradation rates previously published for modules and systems (-0.5% to -0.9% / yr, Jordan et al. 2016). A fleet-scale distribution based on revenue-grade meter data rather than inverter AC (alternating current) data yields a slightly different result. We are working to understand the difference between this result and the inverter-based result of -0.72%/year.

14 SOLAR ENERGY↗
DOE OSTI2021

Assessment of BQ-9000 Biodiesel Properties for 2020 (CRADA CRD-15-593)

Biodiesel producers in the United States and Canada can voluntarily participate in the industry's BQ-9000 quality assurance program. This is the fourth in a series of reports documenting biodiesel quality from participating producers. Participants in the BQ-9000 program were requested to voluntarily provide data to a third-party team. This team anonymized and randomized the data prior to providing to the National Renewable Energy Laboratory (NREL) for analysis and reporting. The critical quality parameters analyzed are: sodium and potassium, calcium and magnesium, phosphorus, flash point and alcohol control, water and sediment, cloud point, acid number, free and total glycerin, monoglycerides, sulfur, oxidation stability, and cold soak filterability test (CSFT). The statistical analysis for these parameters is presented in Table ES-1.

09 BIOMASS FUELS↗
DOE OSTI2023

Annual Site Environmental Report: 2022 (ASER) for the SLAC National Accelerator Laboratory

This report, prepared by the SLAC National Accelerator Laboratory (SLAC) for the U.S. Department of Energy (DOE), SLAC Site Office (SSO), provides a comprehensive summary of the environmental program activities at SLAC for calendar year 2022. Annual Site Environmental Reports (ASERs) are prepared for all DOE sites with significant environmental activities, and distributed to relevant external regulatory agencies and other interested organizations or individuals. To the best of my knowledge, this report accurately summarizes the results of the 2022 environmental monitoring, compliance, and restoration programs at SLAC. This assurance can be made based on SSO and SLAC review of the ASER, and quality assurance protocols applied to monitoring and data analyses at SLAC.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

Annual Site Environmental Report: 2023 (ASER) for the SLAC National Accelerator Laboratory

This report, prepared by the SLAC National Accelerator Laboratory (SLAC) for the U.S. Department of Energy (DOE), SLAC Site Office (SSO), provides a comprehensive summary of the environmental program activities at SLAC for calendar year 2023. Annual Site Environmental Reports (ASERs) are prepared for all DOE sites with significant environmental activities and distributed to relevant external regulatory agencies and other interested organizations or individuals. To the best of my knowledge, this report accurately summarizes the results of the 2023 environmental monitoring, compliance, and restoration programs at SLAC. This assurance can be made based on SSO and SLAC review of the ASER, and quality assurance protocols applied to monitoring and data analyses at SLAC.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Annual Site Environmental Report: 2021 (ASER) for the SLAC National Accelerator Laboratory

This report, prepared by the SLAC National Accelerator Laboratory (SLAC) for the U.S. Department of Energy (DOE), SLAC Site Office (SSO), provides a comprehensive summary of the environmental program activities at SLAC for calendar year 2021. Annual Site Environmental Reports (ASERs) are prepared for all DOE sites with significant environmental activities and distributed to relevant external regulatory agencies and other interested organizations or individuals. To the best of my knowledge, this report accurately summarizes the results of the 2021 environmental monitoring, compliance, and restoration programs at SLAC. This assurance can be made based on SSO and SLAC review of the ASER, and quality assurance protocols applied to monitoring and data analyses at SLAC.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

Pressure-based process monitoring of direct-ink write material extrusion additive manufacturing

As additive manufacturing (AM) has become a reliable method for creating complex and unique hardware rapidly, the quality assurance of printed parts remains a priority. In situ process monitoring offers an approach for performing quality control while simultaneously minimizing post-production inspection. For extrusion printing processes, direct linkages between extrusion pressure fluctuations and print defects can be established by integrating pressure sensors onto the print head. In this work, the sensitivity of process monitoring is tested using engineered spherical defects. Pressure and force sensors located near an ink reservoir and just before the nozzle are shown to assist in identification of air bubbles, changes in height between the print head and build surface, clogs, and particle aggregates with a detection threshold of 60–70% of the nozzle diameter. Visual evidence of printed bead distortion is quantified using optical image analysis and correlated to pressure measurements. Importantly, this methodology provides an ability to monitor the quality of AM parts produced by extrusion printing methods and can be accomplished using commonly available pressure-sensing equipment.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Analysis of Long-Term Quality Control Data for a 137 Cs Dosimetry Calibration Source

Strict quality assurance programs are required for many radiological applications, but these seldom exist for verifying dosimetry calibration sources. After initial characterization of a dosimetry calibration facility, quality control procedures are recommended to ensure the early detection of any changes or malfunctions. These also result in refined knowledge about average dose rate and experimental variations in dose delivery. This paper describes the implementation of a phase I quality control protocol for a 137 Cs dosimetry calibration source and includes an analysis of the resulting data collected over a 24-mo period. During this time, substantial data was collected to establish trial control limits. Air kerma rate measurements were obtained using an ion chamber and were adjusted for decay, corrected for ambient temperature, pressure and humidity, and then analyzed using quality control charts. Three variations of rational subgrouping methods were used in order to find assignable causes of error, and Nelson's Rules were followed to detect any non-random statistical variations. Measurements were subgrouped according to same-day measurements in order to detect positional errors as well as atmospheric correction errors. Additionally, measurements were subgrouped according to analogous experimental setups in order to detect failure in equipment or incorrect settings. Both were analyzed using the X-bar and R chart method. Similarly, individuals and moving ranges charts were used to carefully examine each position in order to observe any situational errors that may occur which include timing, positional, or interference errors. Each method was successful in identifying unique out-of-control data points that occurred during the phase I application of forming control limits. Furthermore, over the 24-mo period, enough data points were deemed in-control to establish reliable trial limits. Future experiments will include the phase II application of gaining more reliable measurements in order to fine-tune the limits, as well as performing a designed experiment, where variables are purposefully changed in order to test the variation of the data.

61 RADIATION PROTECTION AND DOSIMETRY↗
DOE OSTI2021

Code and Solution Verification Assessment of the CTF Thermal Hydraulic Subchannel Code

CTF is a thermal-hydraulics subchannel code jointly developed by Oak Ridge National Laboratory and North Carolina State University. Over the past seven years, the Consortium for Advanced Simulation of Light Water Reactors (CASL) has made a significant investment in developing CTF so it can be used to model light water reactors, including nominal operating conditions, departure from nucleate boiling analysis, and transients ranging from loss of flow to reactivity insertion accidents. In addition to implementing new modeling capabilities and developing the user input and output interface, extensive work has been performed to improve the code’s quality assurance program, resulting in a development process that conforms with NQA-1 requirements. The CASL program follows the Predictive Capability Maturity Model (PCMM) approach for assessing code quality, which emphasizes performing code verification(ensuring the code converges to the correct answer) and solution verification (ensuring the code converges for the intended application). Code and solution verification are used to identify uncertainty errors introduced by numerical approximations in the code and are important for demonstrating that the model is coded without error, which is an important aspect of the Best Estimate plus Uncertainty method. This paper presents a comprehensive overview of the code and solution verification testing that has been performed on CTF. A top-down approach is taken in which the intended CTF applications are presented, followed by the code features required for their modeling. These features are then linked to the applicable code and solution verification tests that demonstrate proper functioning. Past testing efforts are summarized, and new tests are added to help close gaps in the presented test matrix. Rather than performing “one-off” exercises, these tests are added to the automated CTF regression test suite to ensure continual code quality.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2026

Sample Preparation Laboratory (SPL) Best Practices: CGD as the Primary Acceptance Method

The traditional paradigm applied to the construction of nuclear safety related systems, structures, and components (SSCs), like SPL, involves an owner/licensee hiring an EPC firm with an NQA 1 program to manage the engineering, procurement, and construction of the desired SSC. This traditional approach would have posed significant barriers to the successful completion of the SPL. As a smaller capital project, in the $\$$100–$\$$200 million range, there was concern that employing one of the larger EPC companies would escalate costs and extend the projected schedule beyond what would be feasible for the Department of Energy (DOE). The traditional acceptance method employed for nuclear facilities with credited safety functions requires the use of an EPC firm applying American Society of Mechanical Engineers (ASME) NQA 1 nuclear quality assurance (NQA) to accept safety SSCs. In lieu of this approach, INL elected to apply its own NQA 1 program to hire an EPC firm operating a commercial quality program. This method used commercial grade dedication (CGD) as outlined in NQA 1 which had not been applied at this scale. Use of the commercial supply chain was identified as a key factor to the successful completion of SPL. Favorable conditions enabling the use of CGD included: • INL serving as both the designer and the design authority • Design created by an NQA 1 qualified source • A mature CGD program • Availability of a CGD subject matter expert (SME) • A strong construction management program. This white paper elaborates on the methodology employed in the construction of the SPL, the successes achieved, and best practices implemented.

42 - ENGINEERING↗
DOE OSTI2024

Review of In Situ Sensing for Directed Energy Deposition for Industrial Part Quality Assessment

As the use additive manufacturing (AM) processes continues to grow in critical industries, improved quality assurance methods are becoming increasingly sought after for qualification and certification of AM components. Traditional nondestructive evaluation of printed components is often unable to supply the required confidence in print quality to justify qualification and certification, but the layer-by-layer nature of AM provides unprecedented opportunities for in situ quality inspection. This document summarizes recent developments in process monitoring research specifically related to Directed Energy Deposition (DED). Particular attention is given to three aspects of the highlighted manuscripts: (1) the type of sensors used, (2) features extracted from each sensor modality, and (3) analysis of extracted features for AM quality assessment. Based on the review of the state-of-the-art, several observations have been made. First, none of the reviewed works have applied their trained models to real part geometries, with many of the works relying on single track experiments, thin-walled structures, and cubes. Similarly, there have not been any works demonstrating model generalizability, i.e., a model trained on data from one build allows for fruitful analysis of data from another build. Many works used machine learning techniques to distinguish different process regimes (i.e., normal, keyholing, lack-of-fusion), but very few papers have investigated stochastic variation in an already “optimized” process. Sensor fusion approaches are also limited in the DED sensing literature, but the few works that have employed such techniques have demonstrated the benefits. Finally, registration of in situ data to the build coordinate system is of paramount importance to producing industrially relevant in situ monitoring systems. Data registration allows direct correlations between process anomalies detected in the process monitoring data to localized departures in part quality, but such techniques are generally lacking in the current literature.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Real-Time Acoustic Analysis of Batteries

The project explored development and commercialization of an acoustical approach to battery diagnostics. The technology has significant potential impacts for battery manufacturing and quality assurance, battery management during operation, and could be an enabler for the second-life battery market. Research was focused on inspecting and analyzing the physical condition of batteries using ultrasound. This consisted of designing and building hardware for gathering high-quality acoustic data, as well as using battery charge-discharge cyclers and temperature chambers to operate and age the batteries. Over the course of the 2-year program, we were able to build our first prototypes that are robust enough to be used by industry partners to evaluate our technology. Using the same prototypes, we also showed preliminary evidence that our acoustic inspection method may have distinct advantages over standard electrical methods in terms of detecting differences in the physical quality of battery cells. The project also expanded the participant’s core capabilities beyond time-of-flight acoustic measurements.

25 ENERGY STORAGE↗
DOE OSTI2023

Application of Electromagnetic Methods for Reservoir Monitoring with Emphasis on Carbon Capture, Utilization, and Storage

The Controlled-Source ElectroMagnetic (CSEM) method provides crucial information about reservoir fluids and their spatial distribution. Carbon dioxide (CO2) storage, enhanced oil recovery (EOR), geothermal exploration, and lithium exploration are ideal applications for the CSEM method. The versatility of CSEM permits its customization to specific reservoir objectives by selecting the appropriate components of a multi-component system. To effectively tailor the CSEM approach, it is essential to determine whether the primary target reservoir is resistive or conductive. This task is relatively straightforward in CO2 monitoring, where the injected fluid is resistive. However, for scenarios involving brine-saturated (water-wet) or oil-wet (carbon capture, utilization, and storage—CCUS) reservoirs, consideration must also be given to conductive reservoir components. The optimization of data acquisition before the survey involves analyzing target parameters and the sensitivity of multi-component CSEM. This optimization process typically includes on-site noise measurements and 3D anisotropic modeling. Based on our experience, subsequent surveys tend to proceed smoothly, yielding robust measurements that align with scientific objectives. Other critical aspects to be considered are using magnetotelluric (MT) measurements to define the overall background resistivities and integrating real-time quality assurance during data acquisition with 3D modeling. This integration allows the fine tuning of acquisition parameters such as acquisition time and necessary repeats. As a result, data can be examined in real-time to assess subsurface information content while the acquisition is ongoing. Consequently, high-quality data sets are usually obtained for subsequent processing and initial interpretation with minimal user intervention. The implementation of sensitivity analysis during the inversion process plays a pivotal role in ensuring that the acquired data accurately respond to the target reservoirs’ expected depth range. To elucidate these concepts, we present an illustrative example from a CO2 storage site in North Dakota, USA, wherein the long-offset transient electromagnetic method (LOTEM), a variation of the CSEM method, and the MT method were utilized. This example showcases how surface measurements attain appropriately upscaled log-scale sensitivity. Furthermore, the sensitivity of the CSEM and MT methods was examined in other case histories, where the target reservoirs exhibited conductive properties, such as those encountered in enhanced oil recovery (EOR), geothermal, and lithium exploration applications. The same equipment specifications were utilized for CSEM and MT surveys across all case studies.

Barajas-Olalde, César↗
DOE OSTI2020

Crop Modeling Application to Improve Irrigation Efficiency in Year-Round Vegetable Production in the Texas Winter Garden Region

Given a rising demand for quality assurance, rather than solely yield, supplemental irrigation plays an important role to ensure the viability and profitability of vegetable crops from unpredictable changes in weather. However, under drought conditions, agricultural irrigation is often given low priority for water allocation. This reduced water availability for agriculture calls for techniques with greater irrigation efficiency, that do not compromise crop quality and yield, and that provide economic benefit for producers. This study developed vegetable growing models for eight different vegetable crops (bush bean, green bean, cabbage, peppermint, spearmint, yellow straight neck squash, zucchini, and bell pepper) based on data from several years of field research. The ALMANAC model accurately simulated yields and water use efficiency (WUE) of all eight vegetables. The developed vegetable models were used to evaluate the effects of various irrigation regimes on vegetable growth and production in several locations in the Winter Garden Region of Texas, under variable weather conditions. Based on our simulation results from 960 scenarios, optimal irrigation amounts that produce high yield as well as reasonable economic profit to producers were determined for each vegetable crop. Overall, yields for all vegetables increased as irrigation amounts increased. However, irrigation amounts did not have a sustainable impact on vegetable yield at high irrigation treatments, and the WUEs of most vegetables were not significantly different among various irrigation regimes. When vegetable yields were compared with water cost, the rate decreased as irrigation amounts increased. Thus, producers will not receive economic benefits when vegetable irrigation water demand is too high.

Kim, Sumin↗
DOE OSTI2024

A Comprehensive Northern Hemisphere Particle Microphysics Data Set From the Precipitation Imaging Package

Microphysical observations of precipitating particles are critical data sources for numerical weather prediction models and remote sensing retrieval algorithms. However, obtaining coherent data sets of particle microphysics is challenging as they are often unindexed, distributed across disparate institutions, and have not undergone a uniform quality control process. This work introduces a unified, comprehensive Northern Hemisphere particle microphysical data set from the National Aeronautics and Space Administration precipitation imaging package (PIP), accessible in a standardized data format and stored in a centralized, public repository. Data is collected from 10 measurement sites spanning 34° latitude (37°N–71°N) over 10 years (2014–2023), which comprise a set of 1,070,000 precipitating minutes. The provided data set includes measurements of a suite of microphysical attributes for both rain and snow, including distributions of particle size, vertical velocity, and effective density, along with higher-order products including an approximation of volume-weighted equivalent particle densities, liquid equivalent snowfall, and rainfall rate estimates. The data underwent a rigorous standardization and quality assurance process to filter out erroneous observations to produce a self-describing, scalable, and achievable data set. Case study analyses demonstrate the capabilities of the data set in identifying physical processes like precipitation phase-changes at high temporal resolution. Bulk precipitation characteristics from a multi-site intercomparison also highlight distinct microphysical properties unique to each location. This curated PIP data set is a robust database of high-quality particle microphysical observations for constraining future precipitation retrieval algorithms, and offers new insights toward better understanding regional and seasonal differences in bulk precipitation characteristics.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

Radiometric Standards and Best Practices: Recent Progress

International standards and best practices for solar resource assessments provide assurance for traceable measurements associated with a low uncertainty. This benefits the solar energy industry by reducing the investment risks through heightened confidence in the solar resource information. NREL, in collaboration with international organizations, such as subcommittees G03 of ASTM (Radiometry) and TC180/SC1 of ISO (Climate measurement and data), recently revised some standards that are widely used by the solar industry. These include radiometric standards that assist in (i) maintaining calibration traceability; (ii) uncertainty analysis; (iii) measurement quality assurance, and (iv) establishing reference spectral irradiance distributions. The latter are widely used by the solar community to evaluate the actual absorptance, reflectance, and transmittance of solar energy materials, or the performance of solar energy devices and systems, relative to standard conditions. This paper provides a summary of the recent changes brought to these standards as a way to better support the solar energy industry.

industries↗
DOE OSTI2023

SAS4A/SASSYS-1 Commercial Grade Dedication Example Report for a Generic Sodium Pool-Type Fast Reactor Application

In the U.S., a key component of the commercialization of advanced reactors is completion of a license application, which must ultimately be approved by the Nuclear Regulatory Commission (NRC). The approval of the license application by the NRC is contingent on satisfactory demonstration of the design basis and the response of the advanced reactor design to transient and accident scenarios using accepted codes and methods. This report describes the qualification and dedication requirements that the advanced reactor safety analysis system software SAS4A/SASSYS-1 are expected to need to fulfill to be used for sodium-cooled pool-type fast reactor licensing. The qualification and dedication requirements are identified through performance critical characteristics and evaluation model acceptance criteria representative of the advanced reactor design considered for licensing. This document captures, additionally, the verification process developed to demonstrate that the software fulfills the qualification and dedication requirements for a generic sodium-cooled pool-type fast reactor as part of the commercial grade dedication process. Like most software that has primarily existed in the research and development space, the most significant challenge facing SAS4A/SASSYS-1 for use in a licensing framework is the availability of a documentation basis describing the code pedigree. SAS4A/SASSYS-1 has been used for licensing of the fast flux test facility (FFTF) and the JOYO sodium-cooled fast reactor in Japan, as well as the design of the CRBR Plant. However, the historical verification and validation (V&V) activities supporting SAS4A/SASSYS-1 development do not align with modern software quality assurance (SQA) and V&V requirements. Two approaches to use of SAS4A/SASSYS-1 in a commercial licensing framework have been identified: commercial-grade dedication (CGD) and software qualification. The methods and requirements prescribed in the ASME NQA-1-2008/2009 Standard and Regulatory Guide 1.203 on the evaluation model development and assessment process (EMDAP) have been used as guidance to define the CGD and qualification processes, respectively. A qualification and dedication requirements matrix has been developed which utilizes fundamental software verification. In this process, software verification is defined as a software quality process aimed at defining software requirement specifications, developing software design documentation, and performing and documenting acceptance testing of the code against requirements. A key element of software qualification and dedication includes determination of software acceptance with respect to critical characteristics relevant to the functional requirements of the software. To assist with identification of cross-cutting transient phenomena and functional requirements, domestic SFR vendor designs have been reviewed to identify a reference SFR design. For this report, the reference design is defined as a pool-type reactor with metal alloy fuel, a liquid-metal intermediate heat transport system, and passive decay heat rejection systems. Given this reference, a series of high-level cross-cutting phenomena was identified for a general class of single-fault undercooling or reactivity insertion transients that scopes the design basis space, with the goal of assisting with prioritization of documentation development efforts for key transient models in SAS: 1) Reactivity feedback response prior to scram; 2) System-wide thermal inertia; 3) Transition in natural circulation flow regime in heat removal systems; 4) Decay heat generation; 5) Steady-state fuel characterization; 5) Clad/fuel behavior at elevated temperatures; 6) Point kinetics and decay heat; 7) Pump coastdown behavior; 8) Core flow redistribution in loss of forced convection; 9) Pool stratification. As a demonstration of CGD of SAS4A/SASSYS-1 for a sodium pool reactor, a software qualification and dedication gap analysis as it relates to code documentation has been performed. This effort leverages the framework established as part of the SAS4A/SASSYS-1 SQA Program. This CGD demonstration provides a framework that vendors can build upon to demonstrate the applicability of the SAS4A/SASSYS-1 software for licensing a sodium-cooled pool-type fast reactor.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗