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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 289 records · Page 16
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Application of printed strain gauges in prototypical nuclear reactor conditions

This report discusses the current development and testing of additively manufactured temperature sensors and resistive/ capacitive strain gauges. This has potential to improve the sensor design and manufacturing techniques to meet the requirements of in-pile monitoring of mechanical properties and structural health of materials and specimens in current and advanced nuclear test reactors (i.e., in terms of environment conditions, sample geometry, and materials compatibility). The developmental additively manufactured strain gauges are exposed to separate effects testing (i.e., mechanical strain (up to 1000 µe), high temperature (up to 700 °C)) to determine environmental factors that affect the performance of the strain gauge. The robustness and integrity of a printed strain gauge layer exposed to a molten salt environment for up to 500 hours was evaluated, with the goal of assessing material compatibility of printed strain sensors for instrumented surveillance test articles in molten salt reactors. In addition, sensor qualification methodologies are further developed for determining the reliability and robustness at the interface of the additively manufactured strain gauge materials.

36 - MATERIALS SCIENCE↗
DOE OSTI2022

Online Lead/Water Heat Exchanger Sensor/System Feasibility-PNNL (Final Report)

On-line structural health corrosion monitoring in advanced lead fast reactor heat exchangers and molten salt reactor heat exchangers is desirable for detecting tube degradation prior to leaks that may allow mixing of heat exchanger fluids or release of radiological contamination beyond the design containment boundary. This program, On-Line Lead/Water Heat Exchanger Sensor/System Feasibility – PNNL 76092, demonstrates feasibility for an ultrasonic torsional wave mode sensor attached to the outside of a long (30.5-m) heat exchanger tube in the stagnant flow area where the tube joins a heat exchanger plenum and where it is possible to protect a sensor and cable from high-force flows. The sensor must be cable connected to a monitoring instrument near the heat exchanger. The sensor and cable management approach for periodic in-service inspection will be impractical to implement on existing heat exchangers; rather permanently mounted sensors must be installed in conjunction with heat exchanger fabrication. Previous work has shown low-temperature lead zirconate titanate (PZT) piezoceramic sensors are able to detect anomalies of interest in 3.0-m long tubes. These sensors have hereby been extended to a 30.5-m long tube more representative of commercial power heat exchanger designs. The program will continue to investigate higher temperature piezoelectric ceramics and long-term performance of high temperature adhesives and sealants and mechanical pressure coupling for 350-500 °C lead reactor environments and higher temperature (700 °C) molten salt environments.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS1998

Health Monitoring of Composite Material Structures Using a Vibrometry Technique

Non-destructive evaluation (NDE) methods for quantifying and locating damage are essential for inspecting structures to ensure safety and reliability. Transmittance function monitoring is a potentially new NDE technique being tested as a tool to detect, quantify, and locate damage on flexible structures. The technique has a large spatial range that is practical for detecting damage on large composite material structures such as a reusable launch vehicle. The Transmittance Function (TF) theory is based on structural dynamics principles that define how vibration at one point in a structure is related to a force at another point. This relationship is called the Frequency Response Function (FRF). A Transmittance Function (TF) is derived as the ratio of FRFs, and can detect damage because the FRFs change due to damage. If one excitation is used for the testing, the force does not need to be measured to compute the TF. In the damage detection procedure, the structure is subjected to wide-band vibration and TFs are computed between different accelerometers to detect changes in the structure, presumably due to damage. In the first year of the project the TF method was tested on a bolted panel, a curved panel, and beams, all made of fiberglass. It was shown that damage could be detected using low frequency vibration, 250 to 1,250 Hz. The technique is sensitive to damage, but it requires storage of historical or pre-damage TFs for the healthy structure. This would become a large data storage requirement for large structures. Thus one objective for the second year of the project was to eliminate the need to store historical data. The second year report gives details of how storage of historical data was eliminated. Further results of testing panel structures are also given.

Schulz, Mark J.↗
NASA NTRS2017

Baseline-Subtraction-Free (BSF) Damage-Scattered Wave Extraction for Stiffened Isotropic Plates

Lamb waves enable long distance inspection of structures for health monitoring purposes. However, this capability is diminished when applied to complex structures where damage-scattered waves are often buried by scattering from various structural components or boundaries in the time-space domain. Here, a baseline-subtraction-free (BSF) inspection concept based on the Radon transform (RT) is proposed to identify and separate these scattered waves from those scattered by damage. The received time-space domain signals can be converted into the Radon domain, in which the scattered signals from structural components are suppressed into relatively small regions such that damage-scattered signals can be identified and extracted. In this study, a piezoelectric wafer and a linear scan via laser Doppler vibrometer (LDV) were used to excite and acquire the Lamb-wave signals in an aluminum plate with multiple stiffeners. Linear and inverse linear Radon transform algorithms were applied to the direct measurements. The results demonstrate the effectiveness of the Radon transform as a reliable extraction tool for damage-scattered waves in a stiffened aluminum plate and also suggest the possibility of generalizing this technique for application to a wide variety of complex, large-area structures.

He, Jiaze↗
NASA NTRS1989

Sensor technology for smart structures

Advanced aerospace structures are discussed that will very likely be fabricated with integral sensors, actuators, and microprocessors for monitoring and dynamic control of configuration. The concept of 'smart structures' integrates fiber-optic sensor technology with advanced composite materials, whereby the optical fibers are embedded in a composite material and provide internal sensing capability for monitoring parameters which are important for the safety, performance, and reliability of the material and the structure. Along with other research facilities, NASA has initiated a cooperative program to design, fabricate, and test composite trusses, tubes, and flat panels with embedded optical fibers for testing and developing prototype smart structures. It is shown that fiber-optic sensor technology can be combined with advanced material and structure concepts to produce a new class of materials with internal sensors for health monitoring of structures.

Rogowski, R. S.↗
NASA NTRS2015

Modeling of Global BEAM Structure for Evaluation of MMOD Impacts to Support Development of a Health Monitoring System

This report summarizes the initial modeling of the global response of the Bigelow Expandable Activity Module (BEAM) to micrometeorite and orbital debris(MMOD) impacts using a structural, nonlinear, transient dynamic, finite element code. These models complement the on-orbit deployment of the Distributed Impact Detection System (DIDS) to support structural health monitoring studies. Two global models were developed. The first focused exclusively on impacts on the soft-goods (fabric-envelop) portion of BEAM. The second incorporates the bulkhead to support understanding of bulkhead impacts. These models were exercised for random impact locations and responses monitored at the on-orbit sensor locations. The report concludes with areas for future study.

Lyle, Karen H.↗
DOE OSTI2024

Multi-functional cementitious materials with ultra-high damage tolerance and self-sensing ability

Cementitious materials having high damage tolerance and self-sensing ability are described herein. These materials may replace conventional concrete to serve as a major material component for infrastructure systems with greatly improved resistance to cracking, reinforcement corrosion, and other common deterioration mechanisms under service conditions, and prevents fracture failure under extreme events. These materials can also be used for the repair, retrofitting or rehabilitation of existing concrete structures or infrastructure systems. Furthermore, these materials may offer capacity for distributed and direct sensing of cracking, straining and deterioration with spatially continuous resolution wherever the material is located, without relying on installation of sensors. The present invention relates to multifunctional cementitious structural or infrastructure materials that integrate self-sensing with damage tolerance for improving safety, extending service life, and health monitoring of structures, components, and infrastructure systems.

Li, Mo↗
DOE OSTI2020

Fatigue-Crack Detection and Monitoring through the Scattered-Wave Two-Dimensional Cross-Correlation Imaging Method Using Piezoelectric Transducers

Piezoelectric transducers are convenient enablers for generating and receiving Lamb waves for damage detection. Fatigue cracks are one of the most common causes for the failure of metallic structures. Increasing emphasis on the integrity of critical structures creates an urgent need to monitor structures and to detect cracks at an early stage to prevent catastrophic failures. This paper presents a two-dimensional (2D) cross-correlation imaging technique that can not only detect a fatigue crack but can also precisely image the fatigue cracks in metallic structures. The imaging method was based on the cross-correlation algorithm that uses incident waves and the crack-scattered waves of all directions to generate the crack image. Fatigue testing for crack generation was then conducted in both an aluminum plate and a stainless-steel plate. Piezoelectric wafer transducer was used to actuate the interrogating Lamb wave. To obtain the scattered waves as well as the incident waves, a scanning laser Doppler vibrometer was adopted for acquiring time-space multidimensional wavefield, followed with frequency-wavenumber processing. The proof-of-concept study was conducted in an aluminum plate with a hairline fatigue crack. A frequency-wavenumber filtering method was used to obtain the incident wave and the scattered wave wavefields for the cross-correlation imaging. After this, the imaging method was applied to evaluate cracks on a stainless-steel plate generated during fatigue loading tests. The presented imaging method showed successful inspection and quantification results of the crack and its growth.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Smart Composite Pressure Vessels (SCPV) with Integrated Health Monitoring

The U.S. Department of Energy (DOE) is promoting and developing more energy efficient and environmentally friendly technologies that will enable America to use less petroleum. Hydrogen fuel cells – which directly convert the chemical energy in hydrogen to electricity with only water and heat as byproducts – are a very attractive solution that can enable this to happen. To date, DOE's efforts have culminated in commercial demonstration of on-board vehicular hydrogen storage systems that can allow for a driving range of greater than 300 miles. This requires storing 5 Kgs of hydrogen onboard a light vehicle. In order to store this quantity of hydrogen, the hydrogen gas needs to be stored in a composite overwrapped pressure vessel (COPV) at a very high internal pressure. The objective of the program was to demonstrate continuous and predictable health-monitoring of composite pressure vessels. A higher confidence in the operational safety of the vessels will lead to reduced burst factor of safety imposed by regulatory standards and hence will help reduce the structural wall thickness that drives the cost of the vessel. Highly optimized Type III (metal lined) and Type IV (polymer lined) COPVs that are manufactured using filament winding process have been designed and qualified for the above mentioned application. However, the main structural component of the COPVs is carbon fiber and the high cost of carbon fiber composite in a pressure vessel is a primary challenge in reducing the cost of gaseous hydrogen storage. Continuous and remote monitoring of structural health of the COPVs as well as optimization of the strength translation of carbon fibers have the potential to allow for reduced factor of safety, thereby reduced amount of carbon and associated cost of the vessel. In the current program, the project team including Steelhead Composites (SHC), University of Tennessee, Knoxville (UTK), Teijin Carbon America, Oak Ridge National Laboratory (ORNL) and LUNA designed, fabricated, and tested smart composite pressure vessels with integrated sensors. Iterative loops of design and testing using coupons, subscale STEB vessels and full size vessels proved that a new generation of high performance carbon fiber can be used for efficient design of Type 3 vessels for H2 storage. Novel analysis techniques were developed to predict the initiation and propagation of interlaminar damage inside the composite shell due to impact damage, a real threat in practical operation. Such an analysis scheme is typically not used in tank design but is an essential tool for health monitoring of composite vessels. Remote sensing of the key signatures of the tank’s operating parameters such as pressure, acceleration and humidity was demonstrated using a unique device that can wirelessly transmit and stream the data to a remote server. Fiber optic sensors were successfully integrated during fabrication of the tanks. These sensors provide a wealth of information regarding the structural health of the vessel when it is subsequently pressurized or subjected to impact damage. Excellent correlation was demonstrated between the fiber optic sensor and mechanical strain gage data, and between the measurements and analytical predictions.

08 HYDROGEN↗
NASA NTRS2012

Achievable Performance and Effective Interrogator Design for SAW RFID Sensor Tags

For many NASA missions, remote sensing is a critical application that supports activities such as environmental monitoring, planetary science, structural shape and health monitoring, non-destructive evaluation, etc. The utility of the remote sensing devices themselves is greatly increased if they are passive V that is, they do not require any on-board power supply such as batteries V and if they can be identified uniquely during the sensor interrogation process. Additional passive sensor characteristics that enable greater utilization in space applications are small size and weight, long read ranges with low interrogator power, ruggedness, and operability in extreme environments (vacuum, extreme high/low temperature, high radiation, etc.) In this paper, we consider one very promising passive sensor technology, called surface acoustic wave (SAW) radio-frequency identification (RFID), that satisfies all of these criteria. In general, RFID is a method of identifying items using radio waves to interrogate tags encoded with a unique identifier that are affixed to the items of interest. In the case of passive tags, only the interrogator, which transmits power to the tags in the form of radio-frequency electromagnetic radiation, requires access to a power supply. Passive RFID technologies are used today in many applications, including asset tracking and management, security and access control, and remote sensing. To date, most of the development and application in RFID technology has focused on either asset/inventory tracking and control or security and access control because these are the largest commercial application areas. Recently however, there has been growing interest in using passive RFID technology for remote sensing applications, and SAW devices are at the forefront of RFID sensing technology development. Although SAW RFID tags have great potential for use in numerous space-based remote sensing applications, the limited collision resolution capability of current generation tags limits the performance in a cluttered sensing environment. That is, as more SAW-based sensors are added to the environment, numerous tag responses are superimposed at the receiver and decoding all or even a subset of the telemetry becomes increasingly difficult. Background clutter generated by reflectors other than the sensors themselves is also a problem, as is multipath interference and signal distortion, but the limiting factor in many remote sensing applications can be expected to be tag mutual interference. This problem may be greatly mitigated by proper design of the SAW tag waveform, but that remains an open research problem, and in the meantime, several other related questions remain to be answered including: (1) What are the fundamental relationships between tag parameters such as bit-rate, time-bandwidth-product, SNR, and achievable collision resolution? (2) What are the differences in optimal or near-optimal interrogator designs between noise-limited environments and interference-limited environments? (3) What are the performance characteristics of different interrogator designs in term of parameters such as transmitter power level, range, and number of interfering tags? In this paper, we will present the results of a research effort aimed at providing at least partial answers to all of these questions.

Barton Richard J.↗
NASA NTRS2011

Achievable Performance and Effective Interrogator Design for SAW RFID Sensor Tags

For many NASA missions, remote sensing is a critical application that supports activities such as environmental monitoring, planetary science, structural shape and health monitoring, non-destructive evaluation, etc. The utility of the remote sensing devices themselves is greatly increased if they are passive that is, they do not require any on-board power supply such as batteries and if they can be identified uniquely during the sensor interrogation process. Additional passive sensor characteristics that enable greater utilization in space applications are small size and weight, long read ranges with low interrogator power, ruggedness, and operability in extreme environments (vacuum, extreme high/low temperature, high radiation, etc.) In this paper, we consider one very promising passive sensor technology, called surface acoustic wave (SAW) radio-frequency identification (RFID), that satisfies all of these criteria. Although SAW RFID tags have great potential for use in numerous space-based remote sensing applications, the limited collision resolution capability of current generation tags limits the performance in a cluttered sensing environment. That is, as more SAW-based sensors are added to the environment, numerous tag responses are superimposed at the receiver and decoding all or even a subset of the telemetry becomes increasingly difficult. Background clutter generated by reflectors other than the sensors themselves is also a problem, as is multipath interference and signal distortion, but the limiting factor in many remote sensing applications can be expected to be tag mutual interference. This problem may be greatly mitigated by proper design of the SAW tag waveform, but that remains an open research problem, and in the meantime, several other related questions remain to be answered including: What are the fundamental relationships between tag parameters such as bit-rate, time-bandwidth-product, SNR, and achievable collision resolution? What are the differences in optimal or near-optimal interrogator designs between noise-limited environments and interference-limited environments? What are the performance characteristics of different interrogator designs in term of parameters such as transmitter power level, range, and number of interfering tags? In this paper, we present the results of a research effort aimed at providing at least partial answers to all of these questions.

Barton, Richard J.↗
DOE OSTI2021

Feasibility of Lead Fast Reactor Heat Exchanger Tube Online Monitoring

Within virtually all reactor systems with heat exchangers, the thinnest barriers between primary and secondary fluids are the heat exchanger tubes. Consistent with light water reactor experience, the advanced reactor heat exchangers are the most susceptible regions for corrosion and leakage (NRC, 2019). Moreover, traditional inspections and repairs using robotics will be expensive or impractical. On-line structural health corrosion monitoring (OLSHM) is therefore desirable to detect tube degradation prior to leaks that may allow mixing of heat exchanger fluids. Rhetorically many molten salt reactor (MSR) designers plan for on-line monitoring of critical reactor components including heat exchangers but there are no proven OLSHM sensors or systems for MSR heat exchangers. Guided wave ultrasound from the tube-end or ID using conventional low-temperature piezoelectric sensors has been shown to be sensitive to pits and cracks less than 50% through-wall in long pipes and tubes (Narayanan M.M., 2019) . Mode and frequency selection are important for practical sensor design decisions and ultimate performance. The L-0 wave-mode is easily excited by L-mode transducers but they have surface normal wave motion that will be sensitive to and more attenuative because of fluid interaction with the tube surface (Rose J.L., 1994). Shear Horizontal (SH) wave modes have material motion parallel to the tube surface therefore are virtually unaffected by fluid interaction. For SH-0 to be nondispersive in steel, the frequency-thickness product (MHz-mm) must be less than approximately 1.5. SH mode transducers must be coupled by a material that can support shear stress; a thin layer of honey works well for temporary sensors and an adhesive or a brazed metallurgical bond for permanent sensors. If sensors are incorporated into the fabrication process, the same kinds of SH-0 waves can be generated from the stagnant flow area of the tube OD without compromising the heat-exchange tube function. Piezoelectric materials are also available that can withstand harsh temperatures of molten salt heat exchangers (Stevenson T., 2015) (Machura et al., 2008). Though they may not have as high-performance characteristics, their performance only needs to be good enough to detect flaws of interest. This project attempts to demonstrate feasibility to develop a sensor that can be sensitive to flaws of interest and perform long-term monitoring of a molten salt reactor heat exchanger. Benefits to the advanced reactor system include: • Minimizing the expense of a reactor shut down for periodic inspection—only shutdown for cause. • Reduce risk of unexpected tube rupture by detecting flaws before they grow to through-wall leaks. • Cost reduction by minimizing need to design for manual/robotic inspectability. Transducer design, characterization of the beam profile, wedges vs. direct application of piezoelectric sensors, and ultrasonic pulse-echo responses from a representative heat exchange tube with fabricated flaw types are discussed.

On-Line Tube Monitor, Guided Wave Ultrasound, SH-0↗
DOE OSTI2020

Progress Toward Molten Salt Reactor Heat Exchanger On-Line Monitoring

Within virtually all reactor systems with heat exchangers, the thinnest barriers between primary and secondary fluids are the heat exchanger tubes. Consistent with light water reactor experience, the advanced reactor heat exchangers are the most susceptible regions for corrosion and leakage (NRC, 2019). Moreover, traditional inspections and repairs using robotics will be expensive or impractical. On-line structural health corrosion monitoring (OLSHM) is therefore desirable to detect tube degradation prior to leaks that may allow mixing of heat exchanger fluids. Rhetorically many molten salt reactor (MSR) designers plan for on-line monitoring of critical reactor components including heat exchangers but there are no proven OLSHM sensors or systems for MSR heat exchangers. Guided wave ultrasound from the tube-end or ID using conventional low-temperature piezoelectric sensors has been shown to be sensitive to pits and cracks less than 50% through-wall in long pipes and tubes (Narayanan M.M., 2019) . Mode and frequency selection are important for practical sensor design decisions and ultimate performance. The L-0 wave-mode is easily excited by L-mode transducers but they have surface normal wave motion that will be sensitive to and more attenuative because of fluid interaction with the tube surface (Rose J.L., 1994). Shear Horizontal (SH) wave modes have material motion parallel to the tube surface therefore are virtually unaffected by fluid interaction. For SH-0 to be nondispersive in steel, the frequency-thickness product (MHz-mm) must be less than approximately 1.5. SH mode transducers must be coupled by a material that can support shear stress; a thin layer of honey works well for temporary sensors and an adhesive or a brazed metallurgical bond for permanent sensors. If sensors are incorporated into the fabrication process, the same kinds of SH-0 waves can be generated from the stagnant flow area of the tube OD without compromising the heat-exchange tube function. Piezoelectric materials are also available that can withstand harsh temperatures of molten salt heat exchangers (Stevenson T., 2015) (Machura et al., 2008). Though they may not have as high-performance characteristics, their performance only needs to be good enough to detect flaws of interest. This project attempts to demonstrate feasibility to develop a sensor that can be sensitive to flaws of interest and perform long-term monitoring of a molten salt reactor heat exchanger. Benefits to the advanced reactor system include: • Minimizing the expense of a reactor shut down for periodic inspection—only shutdown for cause. • Reduce risk of unexpected tube rupture by detecting flaws before they grow to through-wall leaks. • Cost reduction by minimizing need to design for manual/robotic inspectability. Transducer design, characterization of the beam profile, and ultrasonic pulse-echo responses from a representative heat exchange tube with fabricated flaw types are discussed.

On-Line Tube Monitor, Guided Wave Ultrasound, SH-0↗