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At least 199 records · Page 11

All sources NASA NTRS DOE OSTI

DOE OSTI2024

An experimental process parameter study on the identification of defects in additively fabricated Al6061 with laser powder bed fusion

Additively fabricated metal parts using laser powder bed fusion (L-PBF) possess sophisticated morphology due to the recurrent use of laser-induced metal powder melting and solidification. The surface and 3D morphology of these parts often include defects in the form of protrusions, depressions, pores, voids, keyholes, or cracks that are known to be influenced by laser scanning paths and layer-to-layer processing. Such inconsistent part quality hampers the extensive adoption of L-PBF. Pores and cracks are detrimental to the fatigue life of the parts and components. Quantifying and controlling part defects and optimizing processing and scanning strategy parameters adaptively in real-time through in situ monitoring systems are highly desired. This study investigates the optimization of experimental process parameters (power, scan velocity, and hatch spacing) and their effects on the cracking and porosity of Al6061 alloy using machine learning techniques. Multi-objective optimization is formulated and conducted to determine the L-PBF parameters that minimize both porosity and crack densities.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Potential of deep learning methods to enhance satellite-based monitoring of nuclear power plants focusing on remote operation evaluations

The anticipated expansion of the nuclear industry and the deployment of new nuclear reactors (200 + GW of new nuclear capacity by 2050) require the development of monitoring systems that align with safety and security concerns, providing enhanced evaluation capabilities. A remote monitoring system using satellites and deep learning techniques was evaluated for its ability to detect anomalies and capture various features of nuclear reactors independently of the conditions on the ground. Satellite images of current operational and under-construction nuclear power plants were collected from Google Earth Pro as a surrogate database. Subsequently, five datasets were created from the collected images. Transfer learning technique was used for several classification tasks utilizing VGG16, ResNet50V2, Xception, DenseNet121, and MobileNetV2 pre-trained models. In the first task, the capability of the monitoring system to detect abnormal conditions or processes in a nuclear power plant was investigated. In the second task, the ability to capture operational features remotely was examined. As an example, for the purposes of this study, these features included classifying reactors based on type, power range, or onsite condition. Several evaluation metrics were used to compare the performance of the pre-trained models and the overall monitoring system. Here, the evaluation results demonstrated that deep learning techniques and pre-trained models applied to satellite images have the potential to facilitate further and expand capabilities in monitoring systems to assess plant operation details.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2025

Guidance for Developing Digital Twins for Online Condition Monitoring of Nuclear Power Plant Components

Online condition monitoring is an area of active research that may enable optimized scheduling, maintenance, and safety of nuclear power plant components, reducing unnecessary derates while simultaneously improving operational capacity. Digital twins (DTs) are one avenue to conduct online condition monitoring and are currently being explored by national laboratories and universities alike. DTs for online condition monitoring are, in essence, state concurrent models that emulate a physical process which predicts a parameter and compares it against a measured value. The promise of DT is that they may provide additional insights by combining and interpreting various sources of information and may be used for preventative maintenance scheduling optimization or early fault detection. DTs for condition monitoring are projected to be valuable for meeting requirements under 10 CFR 50.55a and 10 CFR 50.65. However, DT technologies are still under significant development and the process for developing a DT for condition monitoring has not been formalized. Therefore, in this work, we present an initial framework for developing a DT, discuss and review the various challenges and considerations for DT deployment, and identify the opportunities that a DT can improve. Here, the presented framework is intended to help developers formulate a strategy when approaching DT development for condition monitoring. A DT use case for a reactor coolant pump is presented to demonstrate the proposed framework.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2025

Machine Learning for Automated Weld Quality Monitoring and Control

Resistance Spot Welding (RSW) is a critical process in the automotive industry, valued for its cost-effectiveness, short cycle time, and robustness. However, achieving consistent high-quality joints remains challenging due to the complex interplay of various factors, like materials, processes, and manufacturing uncertainties, etc. Under the collaborative project between Oak Ridge National Laboratory (ORNL) and General Motors (GM), we have developed a robust and expansible machine learning (ML) framework aimed at enhancing quality control in RSW. By harnessing the power of machine learning, we have developed the ability to ensure every aspect of the welding process, from the initial process design stage to the final weld joint quality. The framework operates by analyzing a variety of data streams, including in-line process signals, process parameters, materials, and postprocessed weld joint data. Through this analysis, the models have been trained to detect deviations from optimal quality standards, leveraging their ability to identify signature data patterns and anomalies within in-line signals and construct complex correlations between these signals and weld quality parameters. Meanwhile, the machine learning framework is designed to adapt to a variety of materials, including high strength steels and aluminum alloys, etc. Its flexible architecture facilitates the incorporation of diverse data sources and features, enabling precise modeling and prediction across a broad range of material properties and weld quality variables. The expansible ML frameworks represent a promising transformation in weld quality monitoring and control, empowering industry to achieve high levels of efficiency, consistency, and reliability in manufacturing.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2025

Machine Learning for Automated Weld Quality Monitoring and Control

42 ENGINEERING↗

DOE OSTI2024

Modular Subsurface Sensors and Integrated Software for Advanced Subsurface Characterization and Monitoring using Unoccupied Vehicles

The advent and subsequent proliferation of autonomous airborne, waterborne, and groundbased vehicles (i.e., “drones”) promises to broadly transform the geosciences and associated industries, including fossil energy exploration and development, mineral resource exploration and development, water-resource management, and environmental remediation. For geophysical characterization and monitoring, the prospect of programming highly repeatable and low-cost drone missions for subsurface imaging will allow for deployments in hazardous and previously inaccessible areas. Coupled with autonomous workflows for data processing, management, and visualization, drone-based geophysical characterization and monitoring will enable unprecedented, real-time insight into diverse subsurface properties and processes of scientific and engineering importance. Toward this end, the objectives of this Lab Directed Research and Development (LDRD) project were to develop new (1) instrumentation for dronebased electromagnetic induction (EMI) geophysical imaging, including separated transmitter and receivers and associated electronics, (2) software for real-time data telemetry, processing, management, and visualization. Although EMI has been previously deployed using unoccupied aerial systems (UASs), these applications failed to capitalize on the game-changing capabilities of drone platforms. Whereas drone-based data acquisition allows for collection of rich, three-dimensional (3D) multi-offset/multi-angle configurations between transmitters and receivers, past efforts have relied on conventional instrumentation that was designed for ground-based data collection with the transmitter and a single receiver housed in the same unit; nor did these previous applications demonstrate real-time delivery of results to support rapid management decisions in the field. In this 1-year project, we (1) designed and constructed new lightweight independent transmitter and receiver antenna platforms that communicate with a laptop computer; (2) developed software to control data acquisition, manage/transfer data, and visualize data as its collected; and (3) demonstrated the operation of the new hardware and software systems in a ground-based field test. Our work entails major technological advances for EMI and established a foundation on which to build a new drone-based, real-time geophysical EMI imaging capability to support diverse challenges facing the nation.

47 OTHER INSTRUMENTATION↗

DOE OSTI2025

A Performant, Scalable Processing Pipeline for High‐Quality and FAIR Environmental Sensor Data

High-resolution environmental monitoring is necessary to record, understand, and predict biogeochemical and ecological changes particularly in coastal systems but brings significant challenges in processing and making rapidly available the resulting data. The COMPASS-FME project established a network of coastal observational sites across the Chesapeake Bay and western Lake Erie regions extensively instrumented with soil, vegetation, and weather sensors logging data every 15 min. Our data processing framework, written in R and completely open source, prioritizes rapid model-experiment iteration and makes biogeochemical data rapidly available for quality assurance/quality control, analysis, and model ingestion. This pipeline is distinguished by a standardized and modular approach to data curation, extensive metadata and documentation, and its high performance. These attributes combine to make biogeochemical data rapidly accessible across COMPASS-FME and the broader community. Flexible, powerful, and reproducible approaches to handling high-volume environmental data are crucial for accelerating biogeosciences research.

Pennington, Stephanie C. [Pacific Northwest Nation↗

DOE OSTI2025

A Deep Learning-Aided Workflow for Decoding the Stress Regime of Southern Nevada

The Rock Valley fault zone in southern Nevada has a notable history of seismic activity and is the site of a future direct comparison experiment of explosion and earthquake sources. This study aims to gain insight into regional tectonic processes by leveraging recent advances in seismic monitoring capabilities to elucidate the local stress regime. A crucial step in this investigation is the accurate determination of P-wave first-motion polarities, which play a vital role in resolving earthquake focal mechanisms of small earthquakes. Here, we deploy a deep learning-based method for automatic determination of first-motion polarities to vastly expand the polarity dataset beyond what has been reviewed by human analysts. By the integrating P-wave polarities with new measurements of S/P amplitude ratios, we obtain robust focal mechanism estimates for 1306 earthquakes with a local magnitude of 1 and above occurring between 2010 and 2023 in southern Nevada. We then use the focal mechanism catalog to examine the regional stress orientation, confirming an overall trans-tensional stress regime with smaller scale complexities illuminated by individual earthquake sequences. These findings demonstrate how detailed analyses of small earthquakes can provide fundamental information for understanding earthquake processes in the region and inform future experiments at the Nevada National Security Site.

58 GEOSCIENCES↗

DOE OSTI2025

Developing Fluorescence-Based Sensors to Support Rare Earth Element Separation

Rare earth elements (REEs) are essential to most renewable energy technologies. Unfortunately, as we transition to sustainable energy production, the demand for REEs is rapidly growing well beyond current rates of production. As a result, novel means of efficient, scalable, and easily adaptable methods for processing primary and recycle feedstocks are needed. Development and integration of sensors for highly selective in-line monitoring can support more efficient design and testing of such novel separation processes, as well as more cost-effective deployment of those separation flowsheets. Work here will explore the application of fluorescence spectroscopy, a highly sensitive and selective technique, to quantify multiple lanthanides in complex mixtures including known interferents or quenching agents. Results include identification of the optimal excitation wavelength and the limit of detection of various rare earth elements as well as the performance of data-science-based quantification approaches in streams where “unknowns” are present. Overall, the data science tools in conjunction with optical sensor data were able to quantify analytes in the presence of other lanthanides which can be anticipated in the actual industrial stream. Here we include characterization of lanthanides in a microfluidic device similar to those used in new process development. This study demonstrates the capability of utilizing fluorescence spectroscopy to quantify analytes in a complicated solution matrix, suggesting this is a successful approach for in-line monitoring to optimize the separation efficiency in an industrial stream.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

Microstructural Evolution of Tantalum During Deformation and Subsequent Annealing

Microstructure-aware models are necessary to predict the behavior of material based on process knowledge or to extrapolate mechanical properties of materials to environmental conditions which are not easily reproduced in the laboratory, e.g., nuclear reactor environments. Elemental Ta provides a relatively simple BCC system in which to develop a microstructural understanding of deformation processes which can then be applied to more complicated BCC alloys. In situ neutron diffraction during compressive deformation and subsequent heat treatment have been used to monitor the evolution of microstructural features in Ta throughout simulated processing steps. Crystallographic texture and dislocation density are determined as a function of first plastic strain, then temperature. Lattice strains are determined and attributed to stresses at macroscopic, grain and dislocation length scales. The increase of the dislocation density through deformation and subsequent recovery during heat treatment is monitored through the changing diffraction line profile. Also, randomization of the texture is used as a signature of recrystallization. The recovery of dislocations through annihilation is not observed to depend on the initial dislocation density in the range studied here. In contrast, recrystallization is observed to depend strongly on the initially dislocation density.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Fluoride Analysis by Ion Chromatography in Support of Fast Critical Assembly (FCA) Spent Nuclear Fuel Processing

INTRODUCTION The Savannah River Site (SRS) is currently processing Fast Critical Assembly (FCA) fuel received from the Japan Atomic Energy Agency (JAEA) for disposition. Stainless steel-clad plate and rods in stainless steel containers are dissolved using electrolysis with a solution mixture of nitric acid (HNO3), potassium fluoride (KF), and gadolinium (Gd). An ion chromatography (IC) was developed and vetted to monitor fluoride at various sampling points of the process. To finalize the method, FCA test solution was analyzed to qualify the analytical method followed by real FCA process solution analysis using two different analytical columns. This presentation summarizes the development and vetting of the IC method.

White, Thomas L. [Savannah River National Laborato↗

DOE OSTI2026

Establishing an acoustic-property relationship in laser powder bed fusion with machine learning

Quality control of Laser Powder Bed Fusion (PBF-LB) additively manufactured parts is an important hurdle inhibiting the technology’s use structural applications. Acoustic monitoring of the laser powder bed fusion process can detect defects in-situ that are known to degrade mechanical properties. However, processing-structure-property (PSP) relationships are required to extrapolate from detected defects to part performance. Here, this study explores how acoustics may be a suitable signature linking processing conditions to properties, thus effectively substituting for structure in the PSP relationship. Establishing such a relationship would enable a part’s mechanical performance to be directly predicted from its acoustic signature, reducing the need for destructive testing or microstructural analysis to ensure a part will meet performance requirements. One hundred CoCrFeMnNi high entropy alloy tensile bars were printed across 13 process conditions in a series of 6 prints. The acoustic signatures of these tensile bars were used to train machine learning models to predict each part’s mechanical properties. By using both process information and acoustic information to predict mechanical properties, yield strength was predicted 18% more accurately and ductility to failure was predicted 10% more accurately than is achieved when using duplicate parts to predict part performance. Finally, individual acoustic frequencies were investigated to determine why acoustic signatures improve mechanical property predictions and the potential physical origins of these signatures. This work demonstrates how blending acoustics, process information, and machine learning can provide in-situ diagnostics of mechanical properties and improve the reliability of the PBF-LB process.

Acoustic emission↗

DOE OSTI2024

Migration to WebDAV in Belle II Experiment

The usage of WebDAV protocol has become more and more popular within the physics experiments using grid middleware in the last decade, and today it represents a valid alternative to the GridFTP currently supported at best-effort level after the retirement of Globus Toolkit. Belle II experiment established the adoption of WebDAV protocol as the main protocol for data access and third-party-copy transfers, without relying on Storage Resource Manager interface (SRM). The migration process, carried on with continuous and gradual steps, has required a large effort to guarantee a smooth transition maintaining the production infrastructure fully operational. In this contribution we show the transition process, the tool of support developed to monitor step by step the status of third-party-copy support with WebDAV protocol by storages of the collaboration tested in both case pull and push, the strategy adopted to configure DIRAC and the solutions put in place for the corner cases. Finally, we will present some statistics of utilization and we will analyse the achieved results.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2025

The evolution of analytical techniques for multiplex analysis of protein biomarkers

Introduction: The landscape of biomarker development has evolved with advanced analytical technologies, particularly affinity- and mass spectrometry-based techniques. These advancements have deepened our understanding of disease mechanisms, enabling the development of precise diagnostic tools and personalized medicine. Protein biomarkers, which play pivotal roles in biological processes, have become invaluable in diagnosing and monitoring diseases, aided by their presence in various biological samples and the availability of established detection methods. Areas covered: This review covers the role of protein biomarkers in clinical practice, the development and dimensionality of protein biomarkers, advancements in detection technologies, a comparison of these technologies, and future directions in biomarker discovery and disease mechanism elucidation. Expert opinion: Advances in biomarker technologies have the potential to transform diagnostics and personalized treatment but face challenges such as high costs and technical complexity. Enhancing reproducibility and integrating multi-omics approaches may offer better insights. In conclusion, the field should evolve toward high-throughput, automated methods, continuously adapting research, and clinical practices.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2025

OpenSAMPL

OpenSAMPL (Open Synchronization Analytics and Monitoring PLatform) is a Python framework for processing, loading, and managing clock probe time series data and metadata from different vendors.

Grant, Josh [Oak Ridge National Laboratory (ORNL),↗

DOE OSTI2024

EPCAPE-PT-LANL Measurements: NO/NOx Analyzer

Coastal cities offer a unique environment for studying aerosol-cloud interactions and the effects of urban emissions on cloud properties. As part of the Eastern Pacific Cloud Aerosol Precipitation Experiment (EPCAPE), the Partitioning Thrust by Los Alamos National Laboratory (EPCAPE-PT-LANL) was conducted. Our campaign focused on measuring the optical and chemical properties of aerosols and their interactions within marine stratocumulus clouds in La Jolla, California. EPCAPE-PT-LANL enhances the primary goals of EPCAPE through innovative observations of vapor-phase transitions between aerosols and cloud droplets, the impact of black carbon on aerosol-cloud dynamics, and the effects of cloud processing on aerosol optical properties. Instrument: NO2/NO/NOx Monitor (2B-Technology) Header: - NO2_2B[ppb]: Concentration of nitrogen dioxide (NO2) measured at the time of the sampling, expressed in parts per billion. - NO_2B[ppb]: Concentration of nitric oxide (NO) measured at the time of the sampling, expressed in parts per billion. - NOx_2B[ppb]: Total concentration of nitrogen oxides (NOx, which includes NO and NO2) measured at the time of the sampling, expressed in parts per billion.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2024

Topological and Dynamical Representations for Radio Frequency Signal Classification

Radio Frequency (RF) signals are found throughout our world, carrying over-the-air information for both digital and analog uses with applications ranging from WiFi to the radio. One area of focus in RF signal analysis is determining the modulation schemes employed in these signals which is crucial in many RF signal processing domains from secure communication to spectrum monitoring. This work investigates the accuracy and noise robustness of novel Topological Data Analysis (TDA) and dynamic representation based approaches paired with a small convolution neural network for RF signal modulation classification with a comparison to state-of-the-art deep neural network approaches. We show that using TDA tools, like Vietoris-Rips and lower star filtrations, and the Takens' embedding in conjunction with a standard shallow neural network we can capture the intrinsic dynamical, geometric, and topological features of the underlying signal's manifold, offering informative representations of the RF signals. Our approach is effective in handling the modulation classification task and is notably noise robust, outperforming the commonly used deep neural network approaches in mode classification. Moreover, our fusion of dynamical and topological information is able to attain similar performance to deep neural network architectures with significantly smaller training datasets.

Myers, Audun D.↗

DOE OSTI2025

Development of an ERT‐Based Framework for Bentonite Buffers Monitoring From Laboratory Tests: 2. Quantitative Moisture Dynamics Estimation Model

Abstract The long‐term containment of high‐level radioactive waste in geological disposal repositories relies on Engineered Barrier Systems (EBS), with bentonite clay emerging as a candidate material due to its unique properties. Understanding moisture dynamics within bentonite buffers is crucial for EBS performance, as it directly influences the material's swelling capacity, thermal and hydraulic conductivity, mechanical properties, and long‐term evolution under complex thermal‐hydrological‐mechanical (THM) processes. This study develops an advanced Electrical Resistivity Tomography (ERT)‐based framework to quantitatively monitor moisture dynamics under THM conditions. Our framework extends the Waxman‐Smits model to incorporate the coupled effects of temperature, water content, fluid chemistry, and mechanical changes on bentonite's electrical properties. Utilizing HotBENT‐Lab data from our companion paper, which includes electrical conductivity, CT density, and thermocouple measurements, this study offers a novel methodological framework bridging different scales of the model. Our results show that the extended model can estimate water content from ERT data, capturing spatial and temporal variations in moisture distribution within bentonite columns. However, the model tends to overestimate water content compared to CT density‐derived measurements. We address this discrepancy by incorporating a simplified swelling effect model, which improves agreement between ERT and CT density‐based water content estimates. We also discuss model limitations, including simplified treatment of swelling and micropore effects, and propose a conceptual framework for transitioning from laboratory to field applications, addressing challenges such as parameter scalability, field validation methods, and integration of diverse data sources. This ERT‐based framework can potentially advance real‐world moisture monitoring of bentonite‐based EBS in nuclear waste repositories. Plain Language Summary Safely containing high‐level radioactive waste depends on barriers made from materials like bentonite clay, which is effective because it swells and seals in the waste. To ensure these barriers work well over time, it's important to understand how moisture moves through the clay. Our study developed a new method using ERT to monitor moisture levels in bentonite under conditions that mimic those in actual storage sites, including changes in temperature, water content, and mechanical stress. This study improved an existing model to better account for how these factors affect the clay, allowing us to create more accurate moisture maps. Initially, the proposed model overestimated the amount of water in the clay, but its accuracy was improved by factoring in how the clay swells when wet. This study also identified some limitations of the model and suggested ways to adapt it for use in real‐world waste storage sites. This new approach could lead to better monitoring and safety checks for nuclear waste storage systems, helping to ensure long‐term containment. Key Points This work develops an ERT‐based framework extending the Waxman‐Smits model to monitor bentonite moisture dynamics during coupled THM processes The extended model accurately estimates water content from Electrical Resistivity Tomography data, incorporating swelling effects to improve precision This work proposes a conceptual framework for transitioning from laboratory to field applications, advancing EBS monitoring in nuclear waste repositories

Chen, Hang↗