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DOE OSTI2021

Predicting Nugget Size of Resistance Spot Welds Using Infrared Thermal Videos With Image Segmentation and Convolutional Neural Network

Resistance spot welding (RSW) is a widely adopted joining technique in automotive industry. Recent advancement in sensing technology makes it possible to collect thermal videos of the weld nugget during RSW using an infrared (IR) camera. The effective and timely analysis of such thermal videos has the potential of enabling in situ nondestructive evaluation (NDE) of the weld nugget by predicting nugget thickness and diameter. Deep learning (DL) has demonstrated to be effective in analyzing imaging data in many applications. However, the thermal videos in RSW present unique data-level challenges that compromise the effectiveness of most pre-trained DL models. We propose a novel image segmentation method for handling the RSW thermal videos to improve the prediction performance of DL models in RSW. The proposed method transforms raw thermal videos into spatial-temporal instances in four steps: video-wise normalization, removal of uninformative images, watershed segmentation, and spatial-temporal instance construction. The extracted spatial-temporal instances serve as the input data for training a DL-based NDE model. The proposed method is able to extract high-quality data with spatial-temporal correlations in the thermal videos, while being robust to the impact of unknown surface emissivity. Overall, our case studies demonstrate that the proposed method achieves better prediction of nugget thickness and diameter than predicting without the transformation.

42 ENGINEERING↗

DOE OSTI2021

In-Situ Calibrated Digital Process Twin Models for Resource Efficient Manufacturing

The chief objective of manufacturing process improvement efforts is to significantly minimize process resources such as time, cost, waste, and consumed energy while improving product quality and process productivity. This paper presents a novel physics-informed optimization approach based on artificial intelligence (AI) to generate digital process twins (DPTs). The utility of the DPT approach is demonstrated in the case of finish machining of aerospace components made from gamma titanium aluminide alloy (γ-TiAl). This particular component has been plagued with persistent quality defects, including surface and sub-surface cracks, which adversely affect resource efficiency. Previous process improvement efforts have been restricted to anecdotal post-mortem investigation and empirical modeling, which fail to address the fundamental issue of how and when cracks occur during cutting. In this work, the integration of in-situ process characterization with modular physics-based models is presented, and machine learning algorithms are used to create a DPT capable of reducing environmental and energy impacts while significantly increasing yield and profitability. Based on the preliminary results presented here, we report an improvement in the overall embodied energy efficiency of over 84%, 93% in process queuing time, 2% in scrap cost, and 93% in queuing cost has been realized for γ-TiAl machining using our novel approach.

42 ENGINEERING↗

DOE OSTI2025

Detection of Part Porosity in Additive Manufacturing Using Machining

Monitoring of part porosity in additive manufacturing is critical for part qualification and process parameter development. This article describes the monitoring of porosity in additive manufacturing using machining. Grade 91 steel samples with different levels of porosity were additively manufactured using a laser blown-powder process. The samples were machined, and the tool position and cutting power were monitored using the machine controller and an external power transducer, respectively. Results show that the power transducer is sensitive to machining porosities. A novel approach using the standard deviation of cutting power was developed to determine the location of porosities along the length of the machining pass. Test cuts were completed at different machining process parameters. Results showed that the probability of detection was one for pore volume greater than 0.3 mm 3 at different machining parameters. In conclusion, although the detection of porosity using machining is a destructive method for evaluation, it offers a low-cost and fast approach for monitoring porosity in additive manufacturing.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Non-destructive identification of absorptive damage sites by photoluminescence brightening

We present a non-destructive photoluminescence (PL) imaging strategy for probing damage growth behavior in fused silica under laser irradiation. Transient wide-field PL image measurements were conducted at varying excitation intensities to investigate the dynamics of radiative defect generation and annihilation in laser-induced damage sites. Our results reveal that, while low excitation intensities predominantly induce PL quenching due to defect annihilation, high-intensity excitation (>0.3 GW/cm 2 at 532 nm) triggers pronounced PL brightening (PLB), indicative of radiative defect generation. Image analysis demonstrates that PLB events are strongly correlated with subsequent damage growth (10 J/cm 2 at 351 nm), whereas overall PL intensity is not. No optically detectable morphological changes were observed during PLB, confirming the non-destructive nature of the technique. We propose that PLB arises from defect-assisted absorption of multiple photons at pre-existing absorptive centers, which enhances local absorptivity and initiates further defect formation. These findings establish PLB monitoring as a sensitive diagnostic tool for identifying damage sites with elevated absorptivity, enabling targeted maintenance and improved laser damage management in optical materials.

Materials science↗

DOE OSTI2026

Automating Detection and Diagnosis of Faults, Failures, and Underperformance in PV Plants

The project developed hybrid physics-based and machine-learning methods for near-real-time detection of balance-of-system faults (e.g., string, combiner, and tracker outages) in utility-scale Photovoltaic plants, achieving over 50% true positive rates with under 10% false positives and significantly reducing engineering setup time. In the extended phase, the scope expanded to plant-level underperformance analysis and industry benchmarking through the SUPER.epri.com platform. SUPER standardizes data processing and performance metrics across more than 9 GWac and 120+ plants, enabling robust comparisons and insights into loss rates, inverter downtime, and capacity degradation.

14 SOLAR ENERGY↗

NASA NTRS1979

Diagnostics of wear in aeronautical systems

The use of appropriate diagnostic tools for aircraft oil wetted components is reviewed, noting that it can reduce direct operating costs through reduced unscheduled maintenance, particularly in helicopter engine and transmission systems where bearing failures are a significant cost factor. Engine and transmission wear modes are described, and diagnostic methods for oil and wet particle analysis, the spectrometric oil analysis program, chip detectors, ferrography, in-line oil monitor and radioactive isotope tagging are discussed, noting that they are effective over a limited range of particle sizes but compliment each other if used in parallel. Fine filtration can potentially increase time between overhauls, but reduces the effectiveness of conventional oil monitoring techniques so that alternative diagnostic techniques must be used. It is concluded that the development of a diagnostic system should be parallel and integral with the development of a mechanical system.

Wedeven, L. D.↗

NASA NTRS1985

Waterhole auroral arc modification experiments Electrodynamic response

The Waterhole series of experiments, which tested current theories of the electrodynamic structure of auroral arcs, is discussed. In these experiments, the current-carrying capability of the ionospheric plasma was modified by the explosive release of a large number of reactive molecules in the ionospheric F region, with the net effect of reducing the local plasma density over spatial scales comparable to the auroral forms. The response of the aurora to this perturbation was monitored directly by plasma diagnostic instruments on the rocket carrying the explosive release and indirectly from the ground by various photometric and imaging devices. Model predictions of the perturbation induced by the two releases are summarized, and the rocket-borne and ground-based instrumentation is described. Results from both flights are summarized, and a theoretical model is presented which relates the differences in observed response to the topological relationship between the releases and the auroral form.

Whalen, B. A.↗

NASA NTRS1988

Pulsed electron beam emission in space

During the Spacelab-2 mission of July 1985, electron beams (1 keV, 50-150 mA) pulsed at ELF and VLF frequencies were emitted from the Space Shuttle Orbiter. The wave fields generated by the beam were monitored by a Plasma Diagnostics Package which was released as a free-flying subsatellite during a six hour period. Measurements of the Orbiter potential and the return current during beam emissions were obtained from a Charge and Current Probe mounted in the payload bay.

Neubert, T.↗

NASA NTRS1991

Aerothermodynamic radiation studies

We have built and made operational a 6 in. electric arc driven shock tube which alloys us to study the non-equilibrium radiation and kinetics of low pressure (0.1 to 1 torr) gases processed by 6 to 12 km/s shock waves. The diagnostic system allows simultaneous monitoring of shock radiation temporal histories by a bank of up to six radiometers, and spectral histories with two optical multi-channel analyzers. A data set of eight shots was assembled, comprising shocks in N2 and air at pressures between 0.1 and 1 torr and velocities of 6 to 12 km/s. Spectrally resolved data was taken in both the non-equilibrium and equilibrium shock regions on all shots. The present data appear to be the first spectrally resolved shock radiation measurements in N2 performed at 12 km/s. The data base was partially analyzed with salient features identified.

Donohue, K.↗

NASA NTRS1992

The data acquisition system for the Anglo-Australian Observatory 2-degree field project

The Anglo-Australian Observatory (AAO) is building a system that will provide a two-degree field of view at prime focus. A robot positioner will be used to locate up to 400 optical fibers at pre-determined positions in this field. While observations are being made using one set of 400 fibers, the robot will be positioning a second set of fibers in a background field that can be moved in to replace the first when the telescope is moved to a new position. The fibers feed two spectrographs each with a 1024 square CCD detector. The software system being produced to control this involves Vaxes for overall control and data recording, UNIX workstations for fiber configuration calculations and on-line data reduction, and VME systems running VxWorks for real-time control of critical parts such as the positioner robot. The system has to be able to interact with the observatory's present data acquisition systems, which use the ADAM system. As yet, the real-time parts of ADAM have not been ported to Unix, and so we are having to produce a smaller-scale system that is similar but inherently distributed (which ADAM is not). We are using this system as a testbed for ideas that we hope may eventually influence an ADAM II system. The system we are producing is based on a message system that is designed to be able to handle inter-process and inter-processor messages of any length, efficiently, and without ever requiring a task to block (i.e., be unresponsive to 'cancel' messages, enquiry messages), other than when deliberately waiting for external input - all of which will be through such messages. The essential requirement is that a message 'send' operation should never be able to block. The messages will be hierarchical, self-defining, machine-independent data structures. This allows us to provide very simple monitoring of messages for diagnostic purposes, and allows general purpose interface programs to be written without needing to share precise byte by byte message format definitions. Programs in this system have interfaces defined simply in terms of named actions and their parameters. Real-time control programs are required to be able to handle a number of such actions concurrently; data reduction programs will normally only need to handle one action at a time ('process an image', 'display a spectrum', etc).

Shortridge, K.↗

NASA NTRS2002

Software Development for the Hobby-Eberly Telescope's Segment Alignment Maintenance System using LABView

The software development for an upgrade to the Hobby-Eberly Telescope (HET) was done in LABView. In order to improve the performance of the HET at the McDonald Observatory, a closed-loop system had to be implemented to keep the mirror segments aligned during periods of observation. The control system, called the Segment Alignment Maintenance System (SAMs), utilized inductive sensors to measure the relative motions of the mirror segments. Software was developed in LABView to tie the sensors, operator interface, and mirror-control motors together. Developing the software in LABView allowed the system to be flexible, understandable, and able to be modified by the end users. Since LABView is built using block diagrams, the software naturally followed the designed control system's block and flow diagrams, and individual software blocks could be easily verified. LABView's many built-in display routines allowed easy visualization of diagnostic and health-monitoring data during testing. Also, since LABView is a multi-platform software package, different programmers could develop the code remotely on various types of machines. LABView s ease of use facilitated rapid prototyping and field testing. There were some unanticipated difficulties in the software development, but the use of LABView as the software "language" for the development of SAMs contributed to the overall success of the project.

Hall, Drew P.↗

NASA NTRS2013

Investigation of Sideband Index Response to Prototype Gear Tooth Damage

The objective of this analysis was to evaluate the ability of gear condition indicators (CI) to detect contact fatigue damage on spiral bevel gear teeth. Tests were performed in the NASA Glenn Spiral Bevel Gear Fatigue Rig on eight prototype gear sets (pinion/gear). Damage was initiated and progressed on the gear and pinion teeth. Vibration data was measured during damage progression at varying torque values while varying damage modes to the gear teeth were observed and documented with inspection photos. Sideband indexes (SI) and root mean square (RMS) CIs were calculated from the time synchronous averaged vibration data. Results found that both CIs respond differently to varying torque levels, damage levels and damage modes

health monitoring↗

NASA NTRS2017

Successful Validation of RNA Purification and Quantitative Real-Time PCR Analysis of Gene Expression on the International Space Station

The NASA Ames WetLab-2 system was developed to offer new on-orbit gene expression analysis capabilities to ISS researchers and can be used to conduct on-orbit RNA isolation and quantitative real time PCR (RT-qPCR) analysis of gene expression from a wide range of biological samples ranging from microbes to mammalian tissues. On orbit validation included three quantitative PCR (qPCR) runs using an E. coli genomic DNA template pre-loaded at three different concentrations. The flight Ct values for the DNA standards showed no statistically significant differences relative to ground controls although there was increased noise in Ct curves, likely due to microgravity-related bubble retention in the optical windows. RNA was successfully purified from both E. coli and mouse liver samples and successfully generated singleplex, duplex and triplex data although with higher standard deviations than ground controls, also likely due to bubbles. Using volunteer science activities, a potential bubble reduction strategy was tested and resulted in smooth amplification curves and tighter Cts between replicates. The WetLab-2 validation experiment demonstrates a novel molecular biology workbench on ISS which allows scientists to purify and stabilize RNA, and to conduct RT-qPCR analyses on-orbit with rapid results. This novel ability is an important step towards utilizing ISS as a National Laboratory facility with the capability to conduct and adjust science experiments in real time without sample return, and opens new possibilities for rapid medical diagnostics and biological environmental monitoring on ISS.

microgravity↗

DOE OSTI2021

Energy Management Information System Powers NREL's Intelligent Campus

NREL's Intelligent Campus program leverages its own laboratory buildings as research instruments to study renewable energy, energy efficiency, and energy storage, integration, and analysis with real, quantitative measurements. At the heart of NREL's Intelligent Campus program is its Energy Management Information System (EMIS), a family of tools and services used to manage building and campus energy use. NREL's EMIS includes capabilities, such as benchmarking and monthly utility tracking, interval meter analytics, equipment fault detection and diagnostics, condition-based monitoring, and supervisory control, enabling unprecedented energy management capabilities. The system serves as a demonstration project for other federal facilities interested in learning about its design, features, and benefits.

EMIS↗

NASA NTRS2005

A Review of Diagnostic Techniques for ISHM Applications

System diagnosis is an integral part of any Integrated System Health Management application. Diagnostic applications make use of system information from the design phase, such as safety and mission assurance analysis, failure modes and effects analysis, hazards analysis, functional models, fault propagation models, and testability analysis. In modern process control and equipment monitoring systems, topological and analytic , models of the nominal system, derived from design documents, are also employed for fault isolation and identification. Depending on the complexity of the monitored signals from the physical system, diagnostic applications may involve straightforward trending and feature extraction techniques to retrieve the parameters of importance from the sensor streams. They also may involve very complex analysis routines, such as signal processing, learning or classification methods to derive the parameters of importance to diagnosis. The process that is used to diagnose anomalous conditions from monitored system signals varies widely across the different approaches to system diagnosis. Rule-based expert systems, case-based reasoning systems, model-based reasoning systems, learning systems, and probabilistic reasoning systems are examples of the many diverse approaches ta diagnostic reasoning. Many engineering disciplines have specific approaches to modeling, monitoring and diagnosing anomalous conditions. Therefore, there is no "one-size-fits-all" approach to building diagnostic and health monitoring capabilities for a system. For instance, the conventional approaches to diagnosing failures in rotorcraft applications are very different from those used in communications systems. Further, online and offline automated diagnostic applications are integrated into an operations framework with flight crews, flight controllers and maintenance teams. While the emphasis of this paper is automation of health management functions, striking the correct balance between automated and human-performed tasks is a vital concern.

Patterson-Hine, Ann↗

NASA NTRS1993

Gas-grain simulation experiment module conceptual design and gas-grain simulation facility breadboard development

This report delineates the Option portion of the Phase A Gas-Grain Simulation Facility study. The conceptual design of a Gas-Grain Simulation Experiment Module (GGSEM) for Space Shuttle Middeck is discussed. In addition, a laboratory breadboard was developed during this study to develop a key function for the GGSEM and the GGSF, specifically, a solid particle cloud generating device. The breadboard design and test results are discussed and recommendations for further studies are included. The GGSEM is intended to fly on board a low earth orbit (LEO), manned platform. It will be used to perform a subset of the experiments planned for the GGSF for Space Station Freedom, as it can partially accommodate a number of the science experiments. The outcome of the experiments performed will provide an increased understanding of the operational requirements for the GGSF. The GGSEM will also act as a platform to accomplish technology development and proof-of-principle experiments for GGSF hardware, and to verify concepts and designs of hardware for GGSF. The GGSEM will allow assembled subsystems to be tested to verify facility level operation. The technology development that can be accommodated by the GGSEM includes: GGSF sample generation techniques, GGSF on-line diagnostics techniques, sample collection techniques, performance of various types of sensors for environmental monitoring, and some off-line diagnostics. Advantages and disadvantages of several LEO platforms available for GGSEM applications are identified and discussed. Several of the anticipated GGSF experiments require the deagglomeration and dispensing of dry solid particles into an experiment chamber. During the GGSF Phase A study, various techniques and devices available for the solid particle aerosol generator were reviewed. As a result of this review, solid particle deagglomeration and dispensing were identified as key undeveloped technologies in the GGSF design. A laboratory breadboard version of a solid particle generation system was developed and characterization tests performed. The breadboard hardware emulates the functions of the GGSF solid particle cloud generator in a ground laboratory environment, but with some modifications, can be used on other platforms.

Zamel, James M.↗

NASA NTRS2005

Nanomaterials Work at NASA-Johnson Space Center

Nanomaterials activities at NASA-Johnson Space Center focus on single wall carbon nanotube production, characterization and their applications for aerospace. Nanotubes are produced by arc and laser methods and the growth process is monitored by in-situ diagnostics using time resolved passive emission and laser induced fluorescence of the active species. Parametric study of both these processes are conducted to monitor the effect of production parameters including temperature, buffer gas, flow rate, pressure, laser fluence and arc current. Characterization of the nanotube material is performed using the NASA-JSC protocol developed by combining analytical techniques of SEM, TEM, UV-VIS-NIR absorption, Raman, and TGA. Efforts at JSC over the past five years in composites have centered on structural polymernanotube systems. Recent activities broadened this focus to multifunctional materials, supercapacitors, fuel cells, regenerable CO2 absorbers, electromagnetic shielding, radiation dosimetry and thermal management systems of interest for human space flight. Preliminary tests indicate improvement of performance in most of these applications because of the large surface area as well as high conductivity exhibited by SWCNTs.

Arepalli, Sivaram↗

NASA NTRS2006

Hydrocarbon-Fueled Rocket Engine Plume Diagnostics: Analytical Developments and Experimental Results

A viewgraph presentation describing experimental results and analytical developments about plume diagnostics for hydrocarbon-fueled rocket engines is shown. The topics include: 1) SSC Plume Diagnostics Background; 2) Engine Health Monitoring Approach; 3) Rocket Plume Spectroscopy Simulation Code; 4) Spectral Simulation for 10 Atomic Species and for 11 Diatomic Molecular Electronic Bands; 5) "Best" Lines for Plume Diagnostics for Hydrocarbon-Fueled Rocket Engines; 6) Experimental Set Up for the Methane Thruster Test Program and Experimental Results; and 7) Summary and Recommendations.

Tejwani, Gopal D.↗