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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 235 records · Page 13
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Inverting infrasound data for the seismoacoustic source time functions and surface spall at the Source Physics Experiments Phase II: Dry Alluvium Geology

This report presents the infrasound data recorded as part of the Source Physics Experiment - Phase 2, Dry Alluvium Geology. This experiment, also known colloquially as DAG, consisted of four underground chemical explosions at the Nevada National Security Site. We focus our analysis on only the fourth explosion (DAG-4) as we determined that this was the only event that produced clear source-generated infrasound energy as recorded by the DAG sensors. We analyze the data using two inversion methods. The first method is designed to estimate the point-source seismoacoustic source time functions, and the second inversion method is designed to estimate the first-order characteristics (e.g. horizontal dimensions and maximum amplitude) of the actual spall surface. For both analysis methods, we are able to fit the data reasonably well, with various assumptions of the source model. The estimated seismoacoustic source appears to be a combination of a buried, isotropic explosion with a maximum amplitude of ~2 x 10 9 Nm and a vertically oriented force, applied to the Earth's surface with a maximum amplitude of 4 x 10 7 N. We use the vertically oriented force to simulate surface spall. The estimated spall surface has an approximate radius of ~40 m with a maximum acceleration magnitude in the range of 0.8 to 1.5 m/s/s. These estimates are approximately similar to the measured surface acceleration at the site.

58 GEOSCIENCES↗
DOE OSTI2022

Systematic Characterization on Optical and Phonon Properties of Cs[Pb x Sn 1– x ]I 3 Alloyed Perovskites via First-Principles Modeling

Here, understanding the optical properties and phonon thermodynamic features of materials enables the determination of their viability for optoelectronic applications including optical-based gas sensors. Metal halide perovskites ABX 3 as well as their mixed alloys can be attractive in applications of this kind. In particular, the formation of alloyed perovskites A[B x B’ 1–x ]X 3 modulates the functional characteristics that can overtake the single-halide ABX 3 . To this end, we use the first-principles simulations to model the effect of B-site alloying on the optical and phonon properties of cubic Cs[Pb x Sn 1–x ]I 3 (x = 0.75, 0.50, and 0.25). We identified the systematic shifts of optical properties as a function of alloying concentration, such as dielectric constants, refraction indices, and absorption coefficients. It was also found that a linear correlation exists between the optical constants and the band gaps of these materials, which satisfies the Penn model. Modeling of phonons in Cs[Pb x Sn 1–x ]I 3 showed that dissipating the dynamically unstable phonons can be feasible at a carefully chosen alloying concentration, which are originally present in their single-halide Pb- and Sn-ends. Our findings pave a way to optimize the alloying conditions of the alloyed perovskite systems of interest for tuning their optical and phonon stability characteristics.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Embedded sensors integrated into critical components for in situ health monitoring of steam turbines

Operational flexibility is desired in today’s coal-fired power plants to balance power grids by compensating for the variable electricity supply from renewable energy sources and distributed gensets. This demanding requirement accelerates materials degradation and makes in-situ health monitoring essential. Life monitoring of components and subsystems is thus seen as essential in assessing material and mechanical behavior to estimate system reliability, move to a conditionbased maintenance strategy and determine time to failure of the units in their actual operating conditions. Vibration monitoring can be exploited for blade tip timing to measure blade vibration amplitude and tip clearance to detect any deterioration taking place in the condition of steam turbine blades. A failure of a rotating blade can lead to severe turbine damage followed by extensive repairs and loss of power production. A blade vibration monitoring system can help early detection of abnormal blade vibration behavior. In conjunction with a health monitoring system, the vibration characteristics can be analyzed to support a pro-active maintenance and inspection schedule. While the feasibility of this inspection technique has been amply demonstrated, there is a need to install induction probes to magnetize the blade for signal output. Siemens, in partnership with Raytheon Technologies Research Corporation (RTRC), proposes a holistic approach to develop embedded sensors to utilize radio frequency for not only coupling to sensors, but as the sensing modality. The goal of this project is to “embed” the novel sensing approach by using either additively manufactured or extruded waveguides on rotating blades for recording, evaluation and monitoring of blade vibrations in Low Pressure turbines, with applications extending to aero engines

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2021

Introduction of Chalcogenide Glasses to Additive Manufacturing: Nanoparticle Ink Formulation, Inkjet Printing, and Phase Change Devices Fabrication

Abstract Chalcogenide glasses are one of the most versatile materials that have been widely researched because of their flexible optical, chemical, electronic, and phase change properties. Their application is usually in the form of thin films, which work as active layers in sensors and memory devices. In this work, we investigate the formulation of nanoparticle ink of Ge–Se chalcogenide glasses and its potential applications. The process steps reported in this work describe nanoparticle ink formulation from chalcogenide glasses, its application via inkjet printing and dip-coating methods and sintering to manufacture phase change devices. We report data regarding nanoparticle production by ball milling and ultrasonication along with the essential characteristics of the formed inks, like contact angle and viscosity. The printed chalcogenide glass films were characterized by Raman spectroscopy, X-ray diffraction, energy dispersive spectroscopy and atomic force microscopy. The printed films exhibited similar compositional, structural, electronic and optical properties as the thermally evaporated thin films. The crystallization processes of the printed films are discussed compared to those obtained by vacuum thermal deposition. We demonstrate the formation of printed thin films using nanoparticle inks, low-temperature sintering and proof for the first time, their application in electronic and photonic temperature sensors utilizing their phase change property. This work adds chalcogenide glasses to the list of inkjet printable materials, thus offering an easy way to form arbitrary device structures for optical and electronic applications.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Data-Driven Cyber-Attack Detection for PV Farms via Time-Frequency Domain Features

The internetworking of grid-connected power electronics converters (PECs) in photovoltaic (PV) farms has inevitably expanded the cyber-attack surfaces. Here this paper presents a comprehensive study on cyber-attack detection and diagnosis for PEC-enabled PV farms via single waveform sensor to distinguish between normal conditions, open-circuit faults, short-circuit faults, and cyber-attacks. To our knowledge, this has not been attempted before. Firstly, we propose frequency-domain magnitude-based residuals to identify short-circuit faults and a time-domain mean current vector-based feature to distinguish open-circuit faults from other threats. These features can fully reflect the specific physical characteristics of PV farms during threat duration. Secondly, unlike micro phasor measurement units (µPMU) and raw electric waveform-based methods, the proposed innovative features can address novel cyber-attacks that are excluded from the training process. Thirdly, an online hardware-in-the-loop (HIL) testbed using the OPAL-RT real-time digital simulator has verified the effectiveness. The monitoring system runs in real-time while using HIL as an operational solar farm and a National Instruments (NI) data acquisition card as the electric waveform sensor at the point of coupling.

42 ENGINEERING↗
DOE OSTI2023

Seismoacoustic Data Fusion for Ground Coupled Airwaves: a FACT Case Study for Calibration and Array Processing

This report covers an inquiry into seismoacoustic array processing using infrasound arrivals combined with resulting Ground Coupled Airwaves (GCA) that are present on collocated seismic sensors. In preparation, data calibration and denoising is completed for a seismoacoustic sensor array that was deployed at the Facility for Acceptance, Calibration, and Testing on Kirtland Airforce Base from August through September of 2021. The events of interest for this study are small, local explosive sources that lead to short duration, impulsive signals on the instruments. The goal is to determine if combining infrasound signals with the corresponding GCAs on collocated seismic sensors can be used to improve the results returned by automated signal detection and characterization (e.g., back azimuth estimates). Preparation for seismic and infrasound data involves removing the instrument response so that sensors have flat power spectra over the frequency range 0.1-10 Hz, where signal from events of interest may be detected. After instrument response removal, deployment conditions specific to this array require a retrospective noise analysis to determine station emplacement characteristics. Once all data is calibrated, a manual search is performed for possible GCA arrivals across the seismoacoustic network. These arrivals are then processed through beamforming and subsequent event identification, resulting in a catalogue of seismoacoustic GCA arrivals with corresponding back azimuth and trace velocity estimations.

47 OTHER INSTRUMENTATION↗
DOE OSTI2025

Unrolled Video Super-Resolution Network with Autoregressive Prior for the Case of Known Motion

Real-time detection and classification of distant objects is necessary for many national security applications. However, when objects are far from the sensor, they occupy only a small number of pixels in the captured video, limiting the amount of visual detail available for recognition. State-of-the-art classification methods typically rely on high-resolution (HR) video streams to capture characteristic object features, but obtaining such detail is challenging for distant objects that occupy only a few pixels. This motivates the development of video super-resolution (VSR) methods that enhance object classification by recovering fine details from low-pixel representations. Current VSR methods rely either on model-based optimization, which is interpretable but computationally expensive, or on learning-based approaches, which are efficient and high-performing but often lack flexibility and interpretability. In this report, we propose an end-to-end trainable unrolled VSR network, UVSRNet, which super-resolves each frame in a video by exploiting sub-pixel motion between neighboring low-resolution (LR) frames as well as incorporating high-frequency detail from previously super-resolved frames. In particular, by unrolling a plug-and-play (PnP) half-quadratic splitting (HQS) algorithm, we leverage a model-based data-fitting module alongside a learning-based autoregressive prior module. This combination yields a method that maintains the flexibility and interpretability of model-based methods while achieving the performance advantages of learning-based methods.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗
DOE OSTI2023

Evaluation of Neutron-Radiation Tolerance of Lithium Indium Diselenide Semiconductors

Herein we discuss lithium indium diselenide (LISe) as a semiconductor that holds promise for neutron imaging sensor technologies because of its high neutron absorption efficiency and its corresponding ability to discriminate between gamma rays and neutrons. However, being a semiconductor, LISe may not be sufficiently radiation hard for practical application in radiation hard environments. Therefore, a systematic evaluation of the changes in material and electronic properties of LISe after high neutron fluence exposures is investigated. Herein, the characterization methods are utilized which included UV–vis, X-ray diffraction, radioluminescence, Raman, fourier transform infrared spectroscopy (FTIR), current–voltage, and neutron sensing. Characteristics of LISe material that appeared in the literature are identified herein along with several that are expected to appear based on theoretical analyses. The results obtained show clear changes in the material properties of LISe after neutron exposure up to a fluence of 10 16 n cm -2 . However, LISe is still able to sense neutrons above the background at 10 16 n cm -2 , suggesting that LISe may be suitable for use in neutron imaging sensors at neutron imaging facilities.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Improved Gas Plume Identification Using Nearest Neighbor Methods for Background Estimation

Longwave infrared (LWIR) hyperspectral imaging (HSI) can be used for many tasks in remote sensing, including detecting and identifying effluent gases by LWIR sensors on airborne platforms. Identification is used after detection to increase confidence in weakly detected plumes, reduce false positives from detection, and distinguish between similar and confounding material signatures. Background estimation is an important step used to reveal the unique spectral characteristics of the detected gas, allowing the identification model to determine what the gas is specifically. The importance of proper background estimation increases when dealing with weak signals, large libraries of gases of interest, and uncommon or heterogeneous backgrounds. In this article, we propose two methods for background estimation: a novel k-nearest segments (KNS) algorithm and the standard k-nearest neighbors (KNN) algorithm. We test our methods and three existing background estimation methods for comparison against global background estimation to determine which performs best at estimating the true background radiance under a plume and for increasing identification confidence using a neural network classification model. We compare the different methods using 640 simulated weak plumes in an urban environment. For identification, our KNS algorithm improves median neural network identification confidence by 53.2%. For background radiance estimation, the KNN algorithm provides a median of 49 times less RMSE than global background estimation. Furthermore, KNN is the easiest method to tune for different plumes, making it an excellent “out of the box” background estimator.

47 OTHER INSTRUMENTATION↗
DOE OSTI2022

ShupeTurner cloud microphysics

This product is the ShupeTurner cloud microphysics product derived for the Multidisciplinary drifting Observatory for the Study of Arctic Climate (MOSAiC) expedition in the central Arctic. The product includes time-height derivations of the cloud type (phase type) and the condensed water content and characteristic effective particle size for liquid and ice hydrometeor populations. Additionally, it includes the vertical integral of the condensed water content for liquid and ice, i.e., the liquid water path and ice water path. These are derived using a combination of sensors, including: cloud radar, depolarization lidar, microwave radiometer, ceilometer, and radiosondes. During MOSAiC, these sensors were installed and operated onboard the Polarstern icebreaker while within the Arctic sea ice. Most data were obtained while Polarstern was moored to the MOSAiC sea ice floe, passively drifting through the Arctic. However, the data from 16 May 2020 - 17 June 2020 and 31 July 2020 - 21 August 2020 were obtained while Polarstern was underway transiting through the sea ice during relocations of the expedition. General details of the retrieval algorithm, its application, and uncertainties are provided in Shupe et al. (2015), with the cloud classification being described in more detail in Shupe (2007). General details about the MOSAiC expedition including instruments, locations, and meteorological context is provided in Shupe et al. (2022).

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Continuous snow depth and temperature measurements from dense network of above-ground distributed temperature profiling systems from 2021-09-23 to 2024-08-23, Seward Peninsula, Alaska

The dataset contains temperature measurements from distributed temperature profiling (DTP) systems (Dafflon et al., 2022; Wielandt et al., 2022; Wang et al., 2024a; Fiolleau et al., 2024) deployed vertically above the ground surface at a large number of locations from 2021 to 2024. The research is designed to improve understanding of the local heterogeneity in snow depth and snow thermal insulation dynamics, as well as their interactions in a discontinuous permafrost region (Wang et al., 2025). The DTP systems were deployed at 96 locations in a watershed along the Nome-Teller road at mile marker 27 (T27) and at 54 locations on a hillslope along the Kougarok road at mile marker 64 (K64) in the Seward Peninsula, Alaska. The probe location information is stored in Probe_locations_T27.csv and Probe_locations_K64.csv. Temperature measurements were recorded at 15-minute intervals using high-precision digital sensors (accuracy: ±0.1°C, resolution: 0.0078°C). The temperature probes, either 1.4 m or 1.6 m long, contain sensors spaced every 5 cm or 10 cm along their length. The temperature data are stored in compressed files following the format: DTP_snow_air_temperature_(site)_(start)_(end).zip, where site is either T27 or K64, and start and end represent the time series period. Within each ZIP file, individual CSV files are named by probe ID and contain temperature records at different heights above the ground surface.This dataset also includes derived snow depth time series over three snow seasons, estimated from temperature measurements. Snow depth was estimated by identifying the consecutive sensor pair that exhibited the largest drop in high-frequency temperature fluctuations (detailed in the methods). These data are stored in: Snow_depths_flags_(site)_(start)_(end).csv, which includes snow depth time series and corresponding quality flags (defined in the methods) from different probes. Additionally, the dataset includes derived metrics and supporting measurements at selected locations over two snow seasons, contributing to the manuscript of Wang et al., 2025. These locations were chosen based on the availability of high-quality snow depth time series during both seasons. The additional data include: (1) Air temperature proxies measured from the top sensors on the pole when they were not buried by snow, stored in Air_temperature_proxies_(site)_(start)_(end).csv (2) Ground interface temperature, recorded at 3 cm above the ground, stored in Ground_interface_temperature_(site)_(start)_(end).csv (3) Site characteristics, including vegetation height, elevation, and the topographic position index (TPI) within a 50 m radius, stored in Selected_probe_locations_gps_vegheight_tpi_elevation_(site).csv. These metrics were derived from 1 m resolution summer LiDAR-based digital elevation models and digital surface models from Singhania et al., 2023, DOI:10.5440/1832016. Metadata files include data descriptions (_dd.csv) for tabular data. All included files are listed and described in xxxx_flmd.csv.This dataset is an updated version of a previous archive (Wang et al., 2024b, DOI: 10.15485/2475020), incorporating multiple seasons and improved snow depth estimation. Please note that due to large amount of information present in this dataset, many specificities associated with the acquisition of snow temperature, air temperature proxy and estimation of snow depth, and the future archiving of additional datasets on the soil temperature, thaw depth and soil characteristics at these locations, the author would welcome being contacted by people planning to use this dataset.The Next-Generation Ecosystem Experiments: Arctic (NGEE Arctic), was a research effort to reduce uncertainty in Earth System Models by developing a predictive understanding of carbon-rich Arctic ecosystems and feedbacks to climate. NGEE Arctic was supported by the Department of Energy's Office of Biological and Environmental Research.The NGEE Arctic project had two field research sites: 1) located within the Arctic polygonal tundra coastal region on the Barrow Environmental Observatory (BEO) and the North Slope near Utqiagvik (Barrow), Alaska and 2) multiple areas on the discontinuous permafrost region of the Seward Peninsula north of Nome, Alaska.Through observations, experiments, and synthesis with existing datasets, NGEE Arctic provided an enhanced knowledge base for multi-scale modeling and contributed to improved process representation at global pan-Arctic scales within the Department of Energy's Earth system Model (the Energy Exascale Earth System Model, or E3SM), and specifically within the E3SM Land Model component (ELM).

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

An Update on Microreactor Automated Control System (MACS)

Automation of control systems is expected to be important in the economic and safe operation of microreactors. There is a need to develop and demonstrate automated control for microreactors, along with the development of testbeds for this purpose. This report provides updates on the status of a microreactor automated control system (MACS) testbed developed to test control system automation. While a future goal is to demonstrate this system using a prototypic microreactor such as MARVEL, the present focus is on developing and testing within a non-nuclear testbed. The testbed, developed in collaboration with Idaho National Laboratory, includes hardware-in-the-loop simulation and uses a Modelica-based model of a prototypic microreactor for use in testing control automation. Research to date at Oak Ridge National Laboratory has focused on the development of prototypic software for automating plant-level control under selected scenarios. Empirical testing on the integrated MACS testbed was performed to quantify key characteristics of the integrated testbed and to demonstrate the use of the software for automating the calculation and use of actuation setpoints for selected load-following scenarios. Ongoing research is focused on integrating additional control algorithms that utilize data from newly included sensors within the MACS hardware testbed, as well as demonstrating and assessing the performance of the different automated control algorithms on multiple additional operational scenarios.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2026

Surface Energy Modulated Self‐Assembly of Percolative Gallium Nanodroplet Films for Stretchable Electronics

Advancements in soft robotics and wearable technologies have led to an increased need for flexible and stretchable electronic systems. Liquid metals like Gallium (Ga) and its alloys offer high potential in the field of stretchable electronics and photonics due to their inherent high conductivity and malleability. However, their high surface tension and native oxide formation hinder uniform wetting and continuous film formation to get conducting films. Here, we report a fabrication strategy to realize electrically conductive Ga thin films with effective thicknesses around 100 nm on polymeric and elastomeric substrates. By enhancing the surface energy of the elastomer, we create uniform Ga nanodroplets capable of sustaining stretchability up to 200% strain. Our devices exhibit electronic conduction primarily through tunneling and display strain tunable piezoresistive characteristics, which are explained using Kirchhoff's resistive network and Simmon's analytical tunneling current model. To showcase the device's capability in fields of stretchable electronics, we demonstrate several functional prototypes, including flexible devices integrated with Light Emitting Diodes (LEDs), curvature and pressure sensors, and soft robotic grippers capable of sensing object curvature. The demonstrated devices highlight the potential of this approach for scalable integration of stretchable electronics in soft robotic and wearable platforms.

42 ENGINEERING↗
DOE OSTI2020

Quality Assurance methodology for the ATLAS Inner Tracker strip sensor production

The production of the strip sensors for the ATLAS Inner Tracker (ITk) will start in 2020. Nearly 22,000 large area sensors will be produced over a period of about five years by Hamamatsu Photonics K.K. (HPK). The institutes involved in the sensor development and production are committed to deliver and maintain the highest quality sensors for the experiment. A Quality Assurance (QA) strategy has been prepared to be carried out during the whole production period. Once the process has been characterized as providing the required pre-irradiation specifications and the proper radiation hardness, the onus is on the manufacturer to rigidly stick to that qualified process. Still, sample testing with specific device-element structures and irradiation of devices should be implemented by the ITk sensor collaboration. A detailed irradiation and testing plan has been prepared by the ATLAS-ITk Collaboration, together with a newly designed test chip with specific structures to monitor different key technological and device parameters during the whole production. The tests and irradiations will be carried out on a sample basis. In order to have a practical methodology, samples from alternating batches will be sent for irradiations with protons, neutrons and gammas, and then tested in order to check that the characteristics remain within specifications. Here we present the detailed plan and the design and test methods for the structures in the test chip.

47 OTHER INSTRUMENTATION↗
DOE OSTI2023

Multi-Functional Applications of H-Glass Embedded with Stable Plasmonic Gold Nanoislands

Metal nanoparticles (MNPs) are synthesized using various techniques on diverse substrates that significantly impact their properties. However, among the substrate materials investigated, the major challenge is the stability of MNPs due to their poor adhesion to the substrate. Herein, it is demonstrated how a newly developed H-glass can concurrently stabilize plasmonic gold nanoislands (GNIs) and offer multifunctional applications. The GNIs on the H-glass are synthesized using a simple yet, robust thermal dewetting process. The H-glass embedded with GNIs demonstrates versatility in its applications, such as i) acting as a room temperature chemiresistive gas sensor (70% response for NO 2 gas); ii) serving as substrates for surface-enhanced Raman spectroscopy for the identifications of Nile blue (dye) and picric acid (explosive) analytes down to nanomolar concentrations with enhancement factors of 4.8 × 10 6 and 6.1 × 10 5 , respectively; and iii) functioning as a nonlinear optical saturable absorber with a saturation intensity of 18.36 × 10 15 W m -2 at 600 nm, and the performance characteristics are on par with those of materials reported in the existing literature. In conclusion, this work establishes a facile strategy to develop advanced materials by depositing metal nanoislands on glass for various functional applications.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Autonomous Navigation and Control of UGVs' in Nuclear Power Plants - 20381

The purpose of the husky A200 ground robot is to autonomously navigate through the places where it is very hazardous for human beings to reach and operate, like nuclear power plants, chemical industries. The aim is to navigate the ground robot autonomously with an Arm mounted on the robot along with the different sensors as camera, and Lidar. The autonomous motion of the robot is controlled by the controller which uses path planner for trajectory generation of the robot. The mission planner uses the current position of the husky A200, given the way points of the initial and the destination it would extract a best possible route based on the current events provided using GMapping. The global reference frame is used for planning the way points. Creating the appropriate path and the actions required to follow the path are given by the motion planner. The motion planner depends on the active sensor data such as obstacles, lanes, based on the sensor data feasible path is generated. Feasibility of the path is determined by the dynamics of the husky and a series of points generated with certain velocity and acceleration profile. The controller adjusts the lateral, longitudinal and yaw motion of the husky to command the behaviors. The kinematic model is developed for kinematic motion of the husky and the dynamic model is developed for transient and steady state characteristics. The images and other type of data captured by the camera are processed through the computational framework used to build machine learning models. TensorFlow will be used for deep learning and to identify and classify different objects around the husky. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

Sub-millisecond keyhole pore detection in laser powder bed fusion using sound and light sensors and machine learning

Laser powder bed fusion is a mainstream additive manufacturing technology widely used to manufacture complex parts in prominent sectors, including aerospace, biomedical, and automotive industries. However, during the printing process, the presence of an unstable vapor depression can lead to a type of defect called keyhole porosity, which is detrimental to the part quality. In this study, we developed an effective approach to locally detect the generation of keyhole pores during the printing process by leveraging machine learning and a suite of optical and acoustic sensors. Simultaneous synchrotron x-ray imaging allows the direct visualization of pore generation events inside the sample, offering high-fidelity ground truth. A neural network model adopting SqueezeNet architecture using single-sensor data was developed to evaluate the fidelity of each sensor for capturing keyhole pore generation events. Our comparative study shows that the near infrared images gave the highest prediction accuracy, followed by 100 kHz and 20 kHz microphones, and the photodiode sensitive to processing laser wavelength had the lowest accuracy. Using a single sensor, over 90% prediction accuracy can be achieved with a temporal resolution as short as 0.1 ms. A data fusion scheme was also developed with features extracted using SqueezeNet neural network architecture and classification using different machine learning algorithms. Our work demonstrates the correlation between the characteristic optical and acoustic emissions and the keyhole oscillation behavior, and thereby provides strong physics support for the machine learning approach.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Initial Process Planning of a Hybrid Multi-Tasking Platform

Abstract Applications of hybrid technology are expanding from refurbishment and repair to low quantity, specialty part production, which are staple characteristics in medical implant, energy, and aerospace industry sectors, among others. This expansion has led to the development of the Mazak VC-500A/5X AM HWD, a wire fed laser cladding unit equipped with a standard 5 axis CNC. This unit is capable of building near net geometry of complex medium to large parts within a profitable timeframe, due to its comparatively high rate of deposition to that of a powder fed hybrid system. In this study, deposition and machining capabilities of the VC-500A/5X AM HWD are assessed through the production of three different test geometries by different process plans. Production of these test geometries is supported by an open loop sensor package primarily for monitoring machine health, data collection, and machine operator aid. The viability of extended deposition followed by machining is evaluated against a more cyclical strategy of reoccurring deposition and machining operations. Lastly, common defects in as-built geometries are evaluated and addressed through revisions to original process plans and toolpaths, indicating the need for continued innovation in hybrid manufacturing specific CAM/CAD software, as well as closed loop machine monitoring and quality control.

DeWitte, Lisa N.↗