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DOE OSTI2022

Exploring 3D elastic-wave scattering at interfaces using high-resolution phased-array system

The elastic-wave scattering at interfaces, such as cracks, is essential for nondestructive inspections, and hence, understanding the phenomenon is crucial. However, the elastic-wave scattering at cracks is very complex in three dimensions since microscopic asperities of crack faces can be multiple scattering sources. We propose a method for exploring 3D elastic-wave scattering based on our previously developed high-resolution 3D phased-array system, the piezoelectric and laser ultrasonic system (PLUS). We describe the principle of PLUS, which combines a piezoelectric transmitter and a 2D mechanical scan of a laser Doppler vibrometer, enabling us to resolve a crack into a collection of scattring sources. Subsequently, we show how the 3D elastic-wave scattering in the vicinity of each response can be extracted. Here, we experimentally applied PLUS to a fatigue-crack specimen. We found that diverse 3D elastic-wave scattering occurred in a manner depending on the responses within the fatigue crack. This is significant because access to such information will be useful for optimizing inspection conditions, designing ultrasonic measurement systems, and characterizing cracks. More importantly, the described methodology is very general and can be applied to not only metals but also other materials such as composites, concrete, and rocks, leading to progress in many fields.

36 MATERIALS SCIENCE↗

DOE OSTI2021

4D Imaging of ZnO-Coated Nanoporous Al 2 O 3 Aerogels by Chemically Sensitive Ptychographic Tomography: Implications for Designer Catalysts

The 3D chemical structure (4D spectromicroscopy) of nanoporous Al 2 O 3 aerogels coated with ZnO by atomic layer deposition (ALD) was studied by multienergy scanning transmission X-ray microscopy. These materials are representative of a class of designer catalysts in which the nanoporous support is prepared separately from the active catalyst material, which is subsequently introduced by ALD, thereby allowing independent optimization of the morphology, chemistry, and spatial distribution of the support and catalyst. The samples studied were prepared by Ga ion and Xe plasma focused ion beam (FIB) milling as well as drop casting from water suspension. Zn L and Al K edge spectra of six samples with three different ZnO loadings were measured to investigate how loading and different sample preparation methods affect the 3D distribution of the ZnO and Al 2 O 3 . Scanning transmission X-ray microscopy (STXM) and ptychographic imaging at two energies each at the Zn L 3 and Al K edge were measured. The ptychography data were analyzed by using the SHARP reconstruction code to generate quantitative 2D chemical maps of the Al 2 O 3 and the ZnO. The STXM and ptychography maps were then measured at a sequence of tilt angles, covering up to 160° of rotation. The 3D structure of the ZnO and Al 2 O 3 was derived from the tilt series data by tomographic reconstruction using a compressed sensing algorithm. A twodimensional spatial resolution (half-period) of 6 nm, measured by Fourier ring correlation, and a 3D spatial resolution (half-period) of 9 nm, measured by Fourier shell correlation, were achieved when using the COSMIC beamline at the Advanced Light Source (ALS). The results show that for all of the ZnO loadings studied there is nonuniform coverage of the ZnO on the Al 2 O 3 aerogel framework. In addition, we found that both FIB methods create sample artifacts, although the distortion was less with Xe plasma than Ga ion FIB.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Imaging mechanism for hyperspectral scanning probe microscopy via Gaussian process modelling

We investigate the ability to reconstruct and derive spatial structure from sparsely sampled 3D piezoresponse force microcopy data, captured using the band-excitation (BE) technique, via Gaussian Process (GP) methods. Even for weakly informative priors, GP methods allow unambiguous determination of the characteristic length scales of the imaging process both in spatial and frequency domains. We further show that BE data set tends to be oversampled in the spatial domains, with ~30% of original data set sufficient for high-quality reconstruction, potentially enabling faster BE imaging. At the same time, reliable reconstruction along the frequency domain requires the resonance peak to be within the measured band. This behavior suggests the optimal strategy for the BE imaging on unknown samples. Finally, we discuss how GP can be used for automated experimentation in SPM, by combining GP regression with non-rectangular scans.

47 OTHER INSTRUMENTATION↗

DOE OSTI2022

A multi-modal scanning system to digitize CBRNE emergency response scenes

A handheld system developed to digitize a contextual understanding of the scene at a chemical, biological, radiological, nuclear and/or explosives (CBRNE) events is described. The system uses LiDAR and cameras to create a colorized 3D model of the environment, which helps domain experts that are supporting responders in the field. To generate the digitized model, a responder scans any suspicious objects and the surroundings by carrying the system through the scene. The scanning system provides a real-time user interface to inform the user about scanning progress and to indicate any areas that may have been missed either by the LiDAR sensors or the cameras. Currently, the collected data are post-processed on a different device, building a colorized triangular mesh of the encountered scene, with the intention of moving this pipeline to the scanner at a later point. The mesh is sufficiently compressed to be sent over a reduced bandwidth connection to a remote analyst. Furthermore, the system tracks fiducial markers attached to diagnostic equipment that is placed around the suspicious object. The resulting tracking information can be transmitted to remote analysts to further facilitate their supporting efforts. The paper will discuss the system's design, software components, the user interface used for scanning a scene, the necessary procedures for calibration of the sensors, and the processing steps of the resulting data. The discussion will close by evaluating the system's performance on 11 scenes.

Salathe, Marco↗

DOE OSTI2022

A multi-modal scanning system to digitize CBRNE emergency response scenes

Prins, Nicholas↗

DOE OSTI2021

Crystal Plasticity Simulation of Magnesium and Its Alloys: A Review of Recent Advances

Slip and extension twinning are the dominant deformation mechanisms in Magnesium (Mg) and its alloys. Crystal plasticity is a powerful tool to study these deformation mechanisms. Different schemes have incorporated crystal plasticity models to capture different properties, which vary from the simple homogenization Taylor model to the full-scale crystal plasticity finite element model. In the current study, a review of works available in the literature that addresses different properties of Mg and its alloys using crystal plasticity modes is presented. In addition to slip and twinning, detwinning is another deformation mechanism that is activated in Mg and its alloys. The different models that capture detwinning will also be addressed here. Finally, the recent experimental frameworks, such as in-situ neutron diffraction, 3D high energy synchrotron X-ray techniques, and digital image correlation under scanning electron microscopy (SEM-DIC), which are incorporated along crystal plasticity models to investigate the properties of Mg and its alloys, are addressed. Future research directions towards improving the deformation response of Mg and its alloys are identified, which can lead to increased deployment of the lightest structural metal in engineering applications.

36 MATERIALS SCIENCE↗

NASA NTRS2010

Creation of High Resolution Terrain Models of Barringer Meteorite Crater (Meteor Crater) Using Photogrammetry and Terrestrial Laser Scanning Methods

Barringer Meteorite Crater or Meteor Crater, AZ, has been a site of high interest for lunar and Mars analog crater and terrain studies since the early days of the Apollo-Saturn program. It continues to be a site of exceptional interest to lunar, Mars, and other planetary crater and impact analog studies because of its relatively young age (est. 50 thousand years) and well-preserved structure. High resolution (2 meter to 1 decimeter) digital terrain models of Meteor Crater in whole or in part were created at NASA Stennis Space Center to support several lunar surface analog modeling activities using photogrammetric and ground based laser scanning techniques. The dataset created by this activity provides new and highly accurate 3D models of the inside slope of the crater as well as the downslope rock distribution of the western ejecta field. The data are presented to the science community for possible use in furthering studies of Meteor Crater and impact craters in general as well as its current near term lunar exploration use in providing a beneficial test model for lunar surface analog modeling and surface operation studies.

Brown, Richard B.↗

NASA NTRS2021

LiDAR-Inertial Based Navigation and Mapping for Precision Landing

Future lander missions will travel to ambitious, scientifically interesting locations near rough and dangerous terrain. They will need to operate with limited prior information about the terrain, and under varying lighting conditions. Landing safely and precisely in the face of these challenges is difficult for existing vision-based landing systems, which require detailed orbital reconnaissance, a priori hazard maps, and impose time-of-day restrictions on landing to ensure similar lighting conditions in orbital and descent imagery. Advanced 3D imaging LiDAR systems currently under development, and originally intended for single-scan hazard detection, have the potential to be operated continuously from altitudes of up to 5 km. Used together with existing inertial measurement units (IMUs), these sensors open a path-to-flight for a full navigation and mapping system, which could replace or augment a traditional landing sensor suite. A landing system based around these sensors can perform accurate altimetry, map-relative localization (MRL), LiDAR-inertial odometry, and map refinement in an illumination-insensitive manner, over unknown or partially known terrain. This paper outlines preliminary work on a LiDAR-inertial landing system that: estimates the spacecraft trajectory during entry, descent, and landing (EDL); and maps the topography of the terrain below, for future use in hazard detection and avoidance. An incremental, factor graph based, smoothing approach is used to solve for the maximum a posteriori trajectory of spacecraft states. Integrated IMU measurements and features tracked in adjacent range and intensity images are used to estimate motion (LiDAR-inertial odometry). LiDAR scans are binned into motion-corrected digital elevation models (DEMs), which are matched to an existing orbital topographic map to provide absolute position information (MRL). The estimated trajectory is then used to project the LiDAR scans into the map frame, creating a variable-resolution quadtree topographic map suitable for hazard detection and avoidance. Existing topographic maps from throughout the solar system (i.e., Earth, the Moon, Mars, Ceres, Vesta, Europa, Enceladus, and Eros) are upsampled for use in EDL simulations. The Mars 2020 Lander Vision System Simulator (LVSS) is extended to simulate LiDAR-inertial data for realistic EDL trajectories. Results of the algorithm operating on the simulated data are presented. Estimated spacecraft trajectory and refined map are compared to ground truth to assess estimation accuracy.

Katake, Anup↗

DOE OSTI2020

H-Canyon exhaust tunnel LiDAR data request for information review and release

This request is to release LiDAR data files acquired by SRNL R&D Engineering and H-Area Operations and Engineering while performing scans of the interior of the H-Canyon Exhaust tunnel. LiDAR data includes 3-dimensional (3D) point cloud data sets and panoramic digital images of the interior tunnel wall surfaces. Presently two deployments have been completed, the first in November 2019, Fig. 1, and the second in June of 2020. This request is for the release of the data collected during those two deployments. Detailed information on the deployment and data collected can be found in SRS document C-ESR-H-00072, “November 2019 Initial Deployment of LiDAR”. It is planned to perform ongoing scans at approximately 6-month intervals, the purpose of the deployments is to evaluate the usefulness of the data collected to enable quantitative measurements such as tunnel dimensions and rate of surface erosion and as a precursor to a potential deployment of a LiDAR system on the tunnel inspection crawler.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2024

Designing Track for Electrospinning Unit and Cost-Effective Laser Scanning System

Nanofibers are produced in the Targeted Systems Department (TSD) by applying a large voltage to the nanofiber fluid and the collection apparatus known as the electrospinner. The fiber is then shot out of nozzles and collected onto the electrospinner into a nanofiber mat. The problem is that since the nozzle heads are stationary, there is non-uniform deposition of nanofiber on the collection drum leading to variation in thickness of the produced nanofiber mat. To mitigate this issue, a reciprocating mechanism is designed to move the nozzle along the drum collector along with the ability to vary its stroke length. This design was realized using Siemens NX and several parts were printed using a 3D printer, but is, as of writing, untested. Second project involved providing an alternative method to scan a large sample that had undergone certain surface deformation by beam interaction and detect out of plane deformation such as micro-scale swelling and surface roughness. Systems to carry out this scanning already exist; however, they are expensive and produce many files that need to be stitched together and are cumbersome to deal with. The solution is to create a scanning system using an already purchased scanning laser and linear stage motor. The laser and stage motor were combined to produce length results that aligned with a digital microscope but differing height results.

Ruffolo, Leopoldo↗

DOE OSTI2024

Designing a track for an electrospinning unit and cost-effective laser scanning system

Ruffolo, Leopoldo↗

DOE OSTI2020

Robotic Assisted Non-Destructive Testing (NDT)

Mission Statement: Concrete wall characterization for structural integrity evaluation of H-Canyon exhaust tunnel using a remote controlled robotic arm with a NDT Concrete Instrument. Challenges: Rough and Curved Surfaces, Remote location. The UR5 is a collaborative robotic arm capable of: Payload: 11 lbs (5 kg), Reach: 33.5 in (850 mm), Footprint: 5.87 in (149 mm) diameter, Weight: 45.4 Ibs (20.6 kg). The force torque sensor reacts to a set value inputted by the user that can be utilized for sensitive products. This allows the UR5 to react to surfaces using the built-in function to search for a wall and orient itself normal to that plane. The Proceq Pundit 250 array is a nondestructive device that the user applies against a concrete wall and scans using ultrasonic transducers. The back wall and other defects can be show through the touchscreen. A fixture to hold the Proceq Pundit 250 array onto the UR5 robotic arm was designed and 3D printed. It includes openings for easy access to the buttons from the Pundit array as well as a reinforced structural design. The scan from the Pundit array can show the back-wall, rebars, and other defects to assist in determining the structural integrity. In order to scan, a program was made to search for the wall first. 1. The UR5 robotic arm will go to the desired location away from the wall. 2. It will then search for the wall by moving towards it slowly. 3. After contact, the force applied will slowly but steadily increase to a preset value inputted by the user. 4. The force torque sensor will use those values and communicate with the UR5 by adjusting the arm to become normal to the wall. 5. The arm will then apply force to push back the transducers on the Pundit array to avoid gaps. 6. It will then prompt the user to collect data and wait until finished. The UR5 teach pendant allows the user to program the robot to perform automated and repeatable tasks. It includes a free drive mode which allows the user to move the arm to a desired position by hand. The user can also apply restricted planes which include either stopped or slower motion to ensure safety. The concrete sample being tested includes rebars and different grades of surface roughness to understand the readings from the Proceq Pundit 250 array. Desired concrete samples are currently being fabricated that will simulate the terrain being tested.

3D PRINTING↗

DOE OSTI2020

Microstructure reconstruction of battery polymer separators by fusing 2D and 3D image data for transport property analysis

A new approach to generate high-fidelity 3D microstructure reconstructions by leveraging resolution and sample volume characteristics from 2D and 3D microscopy methods is presented here. This approach is employed to model the microstructure of a highly orthotropic polypropylene separator used in lithium-ion batteries, which have challenging multi-scale features of fibrils (<100 nm) and lamellae (>100 nm) to resolve in 3D. Phase contrast nano X-ray computed tomographic data are used to reconstruct the lamellae phase, while 2D scanning electron microscopy data are used to characterize sub-100 nm microstructure features such as the thin fibrils that are beyond the effective resolution of X-ray computed tomography. Fibril geometries are reconstructed stochastically based on the 2D higher resolution data, and integrated with the lamellae geometries in 3D space. Transport property analyses are performed to investigate the bias of microstructure models without considering the fibrils. A sensitivity study is also conducted to facilitate understanding of the relationship between microstructure characteristics and transport properties.

25 ENERGY STORAGE↗

DOE OSTI2020

Bootstrapping mixed correlators in three-dimensional cubic theories II

Conformal field theories (CFTs) with cubic global symmetry in 3D are relevant in a variety of condensed matter systems and have been studied extensively with the use of perturbative methods like the \varepsilon ε expansion. In an earlier work, we used the nonperturbative numerical conformal bootstrap to provide evidence for the existence of a previously unknown 3D CFT with cubic symmetry, dubbed “Platonic CFT”. In this work, we make further use of the numerical conformal bootstrap to perform a three-dimensional scan in the space of scaling dimensions of three low-lying operators. We find a three-dimensional isolated allowed region in parameter space, which includes both the 3D (decoupled) Ising model and the Platonic CFT. The essential assumptions on the spectrum of operators used to provide the isolated allowed region include the existence of a stress-energy tensor and the irrelevance of certain operators (in the renormalization group sense).

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2021

Nondiffractive beam shaping for enhanced optothermal control in metal additive manufacturing

High thermal gradients and complex melt pool instabilities involved in powder bed fusion–based metal additive manufacturing using focused Gaussian-shaped beams often lead to high porosity, poor morphological quality, and degraded mechanical performance. We show here that Bessel beams offer unprecedented control over the spatiotemporal evolution of the melt pool in stainless steel (SS 316L) in comparison to Gaussian beams. Notably, the nondiffractive nature of Bessel beams enables greater tolerance for focal plane positioning during 3D printing. We also demonstrate that Bessel beams significantly reduce the propensity for keyhole formation across a broad scan parameter space. High-speed imaging of the melt pool evolution and solidification dynamics reveals a unique mechanism where Bessel beams stabilize the melt pool turbulence and increase the time for melt pool solidification, owing to reduced thermal gradients. Consequently, we observe a distinctively improved combination of high density, reduced surface roughness, and robust tensile properties in 3D-printed test structures.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Visualizing the Internal Nanocrystallinity of Calcite Due to Nonclassical Crystallization by 3D Coherent X–Ray Diffraction Imaging

The internal crystallinity of calcite is investigated for samples synthesized using two approaches: precipitation from solution and the ammonium carbonate diffusion method. Scanning electron microscopy (SEM) analyses reveal that the calcite products precipitated using both approaches have a well–defined rhombohedron shape, consistent with the euhedral crystal habit of the mineral. The internal structure of these calcite crystals is characterized using Bragg coherent diffraction imaging (BCDI) to determine the 3D electron density and the atomic displacement field. BCDI reconstructions for crystals synthesized using the ammonium carbonate diffusion approach have the expected euhedral shape, with internal strain fields and few internal defects. In contrast, the crystals synthesized by precipitation from solution have very complex external shapes and defective internal structures, presenting null electron density regions and pronounced displacement field distributions. These heterogeneities are interpreted as multiple crystalline domains, created by a nonclassical crystallization mechanism, where smaller nanoparticles coalescence into the final euhedral particles. The combined use of SEM, X–ray diffraction (XRD), and BCDI allows for structurally differentiating calcite crystals grown with different approaches, opening new opportunities to understand how grain boundaries and internal defects alter calcite reactivity.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Virtual Volumes

SAND2022-14692 O Virtual Volumes is a CAD2VR plugin that gives users a powerful and intuitive way of exploring volumetric data in a three-dimensional (3D) virtual reality (VR) environment. It enables viewing of and interaction with volumetric and voxel data derived from sources such computed tomography (CT) scans. Current 2D software solutions for viewing CT scans and other volumetric data forces the user to look through "slices" of their data across anatomical planes. In Virtual Volumes, the user can intuitively interact, scale, crop, colorize, and threshold their data in a 3D VR environment. Sandia National Laboratories is a multimission laboratory managed and operated by National Technology & Engineering Solutions of Sandia, LLC, a wholly owned subsidiary of Honeywell International Inc., for the U.S. Department of Energy’s National Nuclear Security Administration under contract DE-NA0003525.

Krukar, JohnA.↗

DOE OSTI2021

Algorithm-Driven Advances for Scientific CT Instruments: From model-based to deep learning-based approaches

Multiscale 3D characterization is widely used by materials scientists to further their understanding of the relationships between microscopic structure and macroscopic function. Scientific computed tomography (SCT) instruments are one of the most popular choices for 3D nondestructive characterization of materials at length scales ranging from the angstrom scale to the micron scale. These instruments typically have a source of radiation (such as electrons, X-rays, or neutrons) that interacts with the sample to be studied and a detector assembly to capture the result of this interaction (see Figure 1 ). A collection of such high-resolution measurements is made by reorienting the sample, which is mounted on a specially designed stage/holder after which reconstruction algorithms are used to produce the final 3D volume of interest. The specific choice of which instrument to use depends on the desired resolution and properties of the materials being imaged. Additionally, the end goal of SCT scans includes determining the morphology, chemical composition, or dynamic behavior of materials when subjected to external stimuli. In summary, SCT instruments are powerful tools that enable 3D characterization across multiple length scales and play a critical role in furthering the understanding of the structure–function relationships of different materials.

42 ENGINEERING↗