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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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At least 217 records · Page 12
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

In situ melt pool measurements for laser powder bed fusion using multi sensing and correlation analysis

Laser powder bed fusion is a promising technology for local deposition and microstructure control, but it suffers from defects such as delamination and porosity due to the lack of understanding of melt pool dynamics. To study the fundamental behavior of the melt pool, both geometric and thermal sensing with high spatial and temporal resolutions are necessary. This work applies and integrates three advanced sensing technologies: synchrotron X-ray imaging, high-speed IR camera, and high-spatial-resolution IR camera to characterize the evolution of the melt pool shape, keyhole, vapor plume, and thermal evolution in Ti–6Al–4V and 410 stainless steel spot melt cases. Aside from presenting the sensing capability, this paper develops an effective algorithm for high-speed X-ray imaging data to identify melt pool geometries accurately. Preprocessing methods are also implemented for the IR data to estimate the emissivity value and extrapolate the saturated pixels. Quantifications on boundary velocities, melt pool dimensions, thermal gradients, and cooling rates are performed, enabling future comprehensive melt pool dynamics and microstructure analysis. The study discovers a strong correlation between the thermal and X-ray data, demonstrating the feasibility of using relatively cheap IR cameras to predict features that currently can only be captured using costly synchrotron X-ray imaging. Such correlation can be used for future thermal-based melt pool control and model validation.

47 OTHER INSTRUMENTATION↗
DOE OSTI2021

On the Viability of Video Imaging in Leak Rate Quantification: A Theoretical Error Analysis

Optical gas imaging through multispectral cameras is a promising technique for mitigation of methane emissions through localization and quantification of emissions sources. While more advanced cameras developed in recent years have led to lower uncertainties in measuring gas concentrations, a systematic analysis of the uncertainties associated with leak rate estimation have been overlooked. We present a systematic categorization of the involved uncertainties with a focus on a theoretical analysis of projection uncertainties that are inherent to this technique. The projection uncertainties are then quantified using Large Eddy Simulation experiments of a point source release into the atmosphere. Our results show that while projection uncertainties are typically about 5% of the emission rate, low acquisition times and observation of the gas plume at small distances from the emission source (<10 m) can amount to errors of about 20%. Further, we found that acquisition times on the order of tens of seconds are sufficient to significantly reduce (>50%) the projection uncertainties. These findings suggest robust procedures on how to reduce projection uncertainties, however, a balance between other sources of uncertainty due to operational conditions and the employed instrumentation are required to outline more practical guidelines.

47 OTHER INSTRUMENTATION↗
DOE OSTI2021

Completion of Milestone M3CT-21IN0702028 - Receive Welding Module from IFE (Halden, Norway)

Prior to 2018, the U.S. DOE and the commercial nuclear industry relied upon the Halden Reactor Project’s capability to refabricate and reinstrument previously irradiated fuel rods. This capability has now been lost. This activity is key to recovering that capability and enabling the continuation of critical research on commercial and advanced LWR fuels. This welding module completes the three-module suite the Institute For Energy (IFE) was contracted to deliver to INL. This equipment will be used in FY22 to practice techniques developed at IFE for refabricating and instrumenting prototypical fuel rods.

42 ENGINEERING↗
DOE OSTI2020

Sequim Campus Master Plan

Based in Richland, Washington, Pacific Northwest National Laboratory (PNNL) is one of ten U.S. Department of Energy (DOE) Office of Science (SC) national laboratories. PNNL is DOE’s premier chemistry, earth sciences, and data analytics laboratory, delivering vital mission impacts in energy resiliency and national security. PNNL has 19 core capabilities, each a powerful combination of world-class staff, state-of-the- art equipment, and mission-ready facilities. These capabilities represent a collective set of skills and a body of world-leading scientific and engineering work that provides exceptional value and mission delivery to DOE, the National Nuclear Security Administration (NNSA), the U.S. Department of Homeland Security (DHS), and other federal agencies and industry through strategic partnership projects on a not-to-interfere basis. Currently operated by Battelle Memorial Institute, PNNL occupies more than 2.3 million gross square feet (GSF) of buildings and employs approximately 4,700 staff members. PNNL has implemented a rolling 10-year campus strategy, initiated in fiscal year 2013, designed to deliver the foundation for the multidisciplinary science and engineering expertise, equipment, instrumentation, facilities, and infrastructure required to continue providing exceptional value and mission delivery. This strategy is incorporated into PNNL’s annual Laboratory Plan, which serves as DOE-SC’s equivalent of the Five- Year Site Plan required by DOE Order 430.1C Chg. 1, Real Property Asset Management. The PNNL Sequim Campus is located in Clallam County, just outside of Sequim, Washington. PNNL Sequim builds upon a rich history of research related to marine and coastal resources, environmental chemistry, water resources modeling, ecotoxicology, biotechnology, and national security. Facilities at the PNNL Sequim Campus were designed to take advantage of two unique locational assets: the pristine coastal ocean water in Sequim Bay and the region’s exceptionally clean air. Research facilities on the waterfront are supplied with up to 200 gallons per minute (gpm) of seawater and/or groundwater that enables research on aquatic systems ranging from fully seawater to fresh water, with an onsite water treatment system that removes all biological and hazardous chemical residues prior to discharge. Multiple large seawater tanks outside the waterfront laboratories, along with a boat ramp, pier, and floating dock, enable lab-to-field research. The uplands facility takes advantage of the amazing air quality and is built and operated to enable ultratrace chemical/radiological analytical chemistry. This combination of capabilities is not available at any other marine laboratory in the nation.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Design and Characterization of a Burst Mode 20 Mfps Low Noise CMOS Image Sensor

This paper presents a novel ultra-high speed, high conversion-gain, low noise CMOS image sensor (CIS) based on charge-sweep transfer gates implemented in a standard 180 nm CIS process. Through the optimization of the photodiode geometry and the utilization of charge-sweep transfer gates, the proposed pixels achieve a charge transfer time of less than 10 ns without requiring any process modifications. Moreover, the gate structure significantly reduces the floating diffusion capacitance, resulting in an increased conversion gain of 183 µV/e−. This advancement enables the image sensor to achieve the lowest reported noise of 5.1 e− rms. To demonstrate the effectiveness of both optimizations, a proof-of-concept CMOS image sensor is designed, taped-out and characterized.

47 OTHER INSTRUMENTATION↗
DOE OSTI2024

Best Practices for Measuring the Modulation Transfer Function of Video Endoscopes

Endoscopes are crucial for assisting in surgery and disease diagnosis, including the early detection of cancer. The effective use of endoscopes relies on their optical performance, which can be characterized with a series of metrics such as resolution, vital for revealing anatomical details. The modulation transfer function (MTF) is a key metric for evaluating endoscope resolution. However, the 2020 version of the ISO 8600-5 standard, while introducing an endoscope MTF measurement method, lacks empirical validation and excludes opto-electronic video endoscopes, the largest family of endoscopes. Measuring the MTF of video endoscopes requires tailored standards that address their unique characteristics. This paper aims to expand the scope of ISO 8600-5:2020 to include video endoscopes, by optimizing the MTF test method and addressing parameters affecting measurement accuracy. We studied the effects of intensity and uniformity of image luminance, chart modulation compensation, linearity of image digital values, auto gain control, image enhancement, image compression and the region of interest dimensions on images of slanted-edge test charts, and thus the MTF based on these images. By analyzing these effects, we provided recommendations for setting and controlling these factors to obtain accurate MTF curves. Our goal is to enhance the standard’s relevance and effectiveness for measuring the MTF of a broader range of endoscopic devices, with potential applications in the MTF measurement of other digital imaging devices.

47 OTHER INSTRUMENTATION↗
DOE OSTI2023

Correlating armature and needle dynamics with voltage waveforms of solenoid-actuated GDI injector

The injector voltage hump that appears near the needle closing has been used for the real-time monitoring and feedback control of fuel injection duration in modern engines. This voltage hump has been thought to result from the abrupt change in electromagnetic induction by the stoppage of needle motion but detailed electromagnetic processes and associated armature and needle dynamics during the needle closing have not been thoroughly investigated in a wide range of injection conditions, which knowledge is crucial for the delicate control of fuel injection based on the voltage hump. Here, the current study analyzes the transient armature and needle dynamics of a solenoid-actuated gasoline direct injection injector using an X-ray phase-contrast imaging technique. Then, the results are correlated with voltage waveforms during the needle closing transient under various injection pressures, injection pulse durations, and dwell times of split injections. The time derivatives of voltage waveforms showed lower and upper peaks in order in the regime of the voltage hump. Inconsistent with conventional understandings, the lower peak timing of the voltage derivative did not match with the timing of needle closing (end of injection) but rather matched with the abrupt descent timing of the armature and needle. The inflection timing and upper peak timing of the voltage derivative matched with the timings of actual needle closing and armature closing respectively. The amplitude of the voltage hump was near linearly dependent on the needle closing speed. The needle closing speed decreased upon the decrease of injection pulse duration and injection pressure which made it difficult to detect the voltage humps in ballistic injection regimes and low injection pressures. In split injection conditions, the voltage hump of the first injection was not detectable if the dwell time was shorter than the needle closing delay, the time from the current cut-off to the actual needle closing.

42 ENGINEERING↗
DOE OSTI2021

MicroResonators for Compacts Optical Sensors (μRCOS)

As the demand for continuous, in-situ surveillance of health of systems and environments rapidly increases, miniaturized sensors with fast responses are sought. Optical dielectric resonators supporting Whispering Gallery Modes (WGMs) have exceptional properties, like very high-power density, very narrow spectral linewidth, and extremely small mode volume. As the footprint of these sensors is drastically reduced, measurements of microvolumes samples with dramatic reduction in analysis time are possible, enabling large numbers of parallel analyses using microarrays. The high sensitivity and speed of WGM resonators combined with the ability to detect molecules in their native state have great future potential for basic and applied research such as reliable single molecule, trace-gas detection, environmental monitoring, chemical threat sensing, and biodefense Such appealing peculiarities motivated us developing WMG resonators (WGMRs) for Cavity Enhanced Absorption Spectroscopy (CEAS) for chem-bio detection. Specifically, we designed and batch-fabricated microspheres and fiber tapers for resonances excitation. We successfully detected gases (N 2 and CO 2 ) in customized environmental chambers, and bio-organisms (Inf. A and E. Coli) with integrated microfluidic systems. Background calibration and environmental isolation were always accounted for in proving the performances.

36 MATERIALS SCIENCE↗
DOE OSTI2022

A Systems Engineering Analysis of National Ignition Facility Industrial Controls Systems and Safety Interlock Systems Remote Input/Output Networking Migration from ControlNet to EtherNet/IP

The ControlNet industrial communications protocol and modules used in the Industrial Control System (ICS) and Safety Interlock System (SIS) at the National Ignition Facility (NIF) are no longer necessary and the ICS and SIS would be better served by migrating the communications structure to use EtherNet/Industrial Protocol (IP) and EtherNet bridge modules instead. By the admission of the vendor of ControlNet hardware, Rockwell Automation, in literature by Bill Petro [1], “Moving forward, customers will be able to optimize their asset utilization better using EtherNet/IP protocol than with ControlNet.” The NIF is one of the key elements of the Inertial Confinement Fusion (ICF) program at Lawrence Livermore National Laboratory (LLNL), a federally funded research and development center (FFRDC). The NIF contains the systems and provides the operational capacity to perform ICF, high energy density (HED), and discovery science experiments utilizing 192 individual beamlines, a host of diagnostics, and all the industrial systems required to facilitate these beamlines and diagnostics. The industrial systems are governed by the ICS and SIS, with the ICS providing control and the SIS providing monitoring and permissives. Construction on the NIF began in 1997 and was certified complete in 2009 and, as a result, the ICS and SIS were developed during this time using the tools that were available then. This includes the communications structure and protocols for these systems, much of which was, and still is, ControlNet. ControlNet, particularly during the time that the ICS and SIS were being built, has several attractive features. ControlNet hardware is exclusive to Rockwell Automation, which was the automation hardware chosen for the ICS and SIS. One feature that could be considered an advantage or a disadvantage depending on the communication needs of the system is that ControlNet also utilizes no active network components, excluding repeaters which are not always necessary. According to the architect of the ICS system at the NIF, Gordon Lau, one of the most attractive features of the ControlNet protocol during development of the ICS and SIS was that it is deterministic, providing timing of data transfer that is executed exactly as it is defined by the developer.

42 ENGINEERING↗
DOE OSTI2021

Digital Engineering Sensor Architectures for Future Microreactor Builds

The development of new nuclear reactors continues to be high risk during the construction phase, with many programs exceeding their budget by 2–3×. This work entails an investigation of sensors that can be utilized during the construction of microreactors and their incorporation into a digital twin supporting the construction process. These sensors can be used to monitor construction progress, inform of variances from the expected design, and verify that the reactor is being built to the planned building information management model. This will ensure reactor equipment and components accurately interact through welding or additive manufacturing technologies. This study illustrates the importance of the digital engineering architecture for microreactor deployment.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

A heat flux sensor leveraging the transverse Seebeck effect in elemental antimony

Certain configurations of anisotropic single crystal materials can generate a thermoelectric voltage orthogonal to an induced temperature gradient. This phenomenon is known as the Transverse Seebeck Effect (TSE) and can be leveraged to fabricate simple and robust heat flux sensors. Only a small number of materials have been considered as TSE-based transducers and, among these, few have been developed into sensors with ruggedization against chemical and mechanical degradation. Here, we report on the fabrication and characterization of a rugged TSE-based heat flux sensor using prismatic antimony single crystals. The heat flux sensor was tested under static and dynamic heating scenarios. The sensor has a linear responsivity of 16.8 µV/(W/cm2) to heat fluxes spanning more than two orders of magnitude and a time constant of 4.4 s. The sensor’s response to localized heating, probed with a laser scanning technique, validated that the transduction mechanism is primarily the TSE by ruling out a sizable contribution from the conventional Seebeck effect. Finite element analysis corroborated that components used in the sensor package are the primary determinants of the time constant and the decrement of the responsivity from its theoretical maximum. Design principles that may be applied to elicit a faster transient response or higher responsivity are proposed. Furthermore, the results establish single crystal antimony as a promising transducer material for heat flux measurement systems and demonstrate potential effects of ruggedization on sensor performance.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Joint Actinide Shock Physics Experimental Research (JASPER): System Design Requirements: Trigger Unit

One of the key systems required for the Joint Actinide Shock Physics Experimental Research (JASPER) facility is the timely triggering of the Prompt System (PS). The Trigger Unit (TU) is the critical component that determines when the PS is to be triggered. There are two redundant TUs within the JASPER system, and each TU creates three redundant triggers for the PS. In this fashion, the Prompt Trigger System (PTS) can suffer the loss of one sensor, as well as the loss of one TU, and still function correctly. The TU is designed to receive signals from five separate sensors along the flight of the projectile on its way to the target. The TU uses three pairs of these detectors to create a trigger pulse at the appropriate time, based on the actual velocity of the projectile as it passes between the two sensors.

42 ENGINEERING↗
DOE OSTI2024

Enhancing Camera Calibration for Traffic Surveillance with an Integrated Approach of Genetic Algorithm and Particle Swarm Optimization

Recent advancements in sensor technologies, coupled with signal processing and machine learning, have enabled real-time traffic control systems to effectively adapt to changing traffic conditions. Cameras, as sensors, offer a cost-effective means to determine the number, location, type, and speed of vehicles, aiding decision-making at traffic intersections. However, the effective use of cameras for traffic surveillance requires proper calibration. This paper proposes a new optimization-based method for camera calibration. In this approach, initial calibration parameters are established using the Direct Linear Transformation (DLT) method. Then, optimization algorithms are applied to further refine the calibration parameters for the correction of nonlinear lens distortions. A significant enhancement in the optimization process is achieved through the integration of the Genetic Algorithm (GA) and Particle Swarm Optimization (PSO) into a combined Integrated GA and PSO (IGAPSO) technique. The effectiveness of this method is demonstrated through the calibration of eleven roadside cameras at three different intersections. The experimental results show that when compared to the baseline DLT method, the vehicle localization error is reduced by 22.30% with GA, 22.31% with PSO, and 25.51% with IGAPSO.

47 OTHER INSTRUMENTATION↗
DOE OSTI2023

Towards Three-Dimensional Neutron Imaging with Light-field Technology

A broad range of applications in nuclear safeguards and security can benefit from compact, fast neutron imagers with large angular acceptance. However, accurate 3D multi-vertex reconstruction in a monolithic detector remains a significant barrier to realization. Current approaches, such as the centroiding approach and the use of shadow masks, have not yet resulted in a successful demonstration in a light-starved environment. This project explored the use of cutting-edge technology—a light field camera—which inherently preserves both the spatial and directional information of incident light. Such technology can, in principle, resolve multi-vertex events and offer accurate position reconstruction in 3D with relatively simple readout electronics. Since the project's inception in May 2023, we have built an experimental setup to calibrate and characterize a commercial light-field camera (Lytro Illum). We assessed its 3D event reconstruction capability in a relatively low-light intensity environment by analyzing the cross-correlation of a series of 2D images of a characterized tunable light source taken at various distances. A sub-cm resolution, lower than typical neutron interaction separations in a compact scintillator volume, was observed with the LED light source, suggesting the promising capability of its nominal optics design to provide the adequate resolution required for a compact monolithic neutron directional detector. However, using a light-field-based readout for a neutron camera requires incorporating an ultra-low-noise light sensor, which is beyond the scope of this project. We also initiated the development of a 3D light-field-based reconstruction algorithm tailored to sparse scenes, as expected from particle interactions in a scintillator medium. Additionally, we demonstrated the capability of the algorithm to replicate the ground truth. Finally, we began the development of a neutron directional detector simulation to determine the performance criteria for light-field-based reconstruction that allows for good neutron directional reconstruction. This Feasibility Study has led to a successful follow-up project under the DNN R&D innovation portfolio starting May 2024.

42 ENGINEERING↗
DOE OSTI2023

TFR-2574 MARVEL Instrumentation and Control System (ICS)

This document contains the Level 3 requirements associated with the subsystems of the Instrumentation Control System (ICS) in the Microreactor Applications Research Validation and Evaluation (MARVEL) project.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2020

Lidar-based remote infrared gas sensor for monitoring anthropogenic pollution: a proof of concept

We propose using wavelength-modulation laser absorption spectroscopy in combination with quadrature detection of scattered light for remote industrial pollution monitoring in the atmosphere with a compact lidar-based gas sensor, which can be mounted on board an unmanned aerial vehicle. The instrument can be used for detecting leaks in product pipe lines; monitoring toxic gases near landfill sites, waste incineration plants, and other hazardous man-made facilities; analysing the gas atmosphere in industrial buildings and structures; and monitoring engineering processes at a sensitivity level of tens of ppm m in gas concentration measurements at characteristic distances of tens of metres. (laser applications and other issues in quantum electronics)

42 ENGINEERING↗