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At least 343 records · Page 19

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NASA NTRS2001

Thin Film Sensors for Surface Measurements

Advanced thin film sensors that can provide accurate surface temperature, strain, and heat flux measurements have been developed at NASA Glenn Research Center. These sensors provide minimally intrusive characterization of advanced propulsion materials and components in hostile, high-temperature environments as well as validation of propulsion system design codes. The sensors are designed for applications on different material systems and engine components for testing in engine simulation facilities. Thin film thermocouples and strain gauges for the measurement of surface temperature and strain have been demonstrated on metals, ceramics and advanced ceramic-based composites of various component configurations. Test environments have included both air-breathing and space propulsion-based engine and burner rig environments at surface temperatures up to 1100 C and under high gas flow and pressure conditions. The technologies developed for these sensors as well as for a thin film heat flux gauge have been integrated into a single multifunctional gauge for the simultaneous real-time measurement of surface temperature, strain, and heat flux. This is the first step toward the development of smart sensors with integrated signal conditioning and high temperature electronics that would have the capability to provide feedback to the operating system in real-time. A description of the fabrication process for the thin film sensors and multifunctional gauge will be provided. In addition, the material systems on which the sensors have been demonstrated, the test facilities and the results of the tests to-date will be described. Finally, the results will be provided of the current effort to demonstrate the capabilities of the multifunctional gauge.

Martin, Lisa C.↗

DOE OSTI2023

X-ray wavefront sensor development at the Advanced Light Source

At Lawrence Berkeley National Laboratory's Advanced Light Source, we are developing x-ray wavefront sensors to support the creation and operation of beamlines with diffraction-limited quality. Our new approach to rapid, intermittent wavefront sensing operates in reflection at glancing incidence angles and is compatible with the high-power densities of modern beamlines. For soft x-ray applications especially, the wavefront sensor can operate upstream of the exit slit in a vertically dispersed beam. This single-shot technique supports lateral shearing interferometry and Hartmann wavefront sensing; it can be adapted to speckle-based techniques as well. The reflected beam is directed to an off-axis YAG crystal that produces scintillated visible light. A small mirror reflects the light to a microscope and camera, and the measured wavefront shape information can be used as feedback to adaptive x-ray mirror elements. A compact array of gratings enables measurement across a broad range of photon energies or wavefront curvatures. We describe recent demonstrations at soft x-ray and hard x-ray wavelengths measuring an adaptive x-ray mirror, and a toroidal focusing mirror.

Goldberg, Kenneth A↗

NASA NTRS1993

Advanced data visualization and sensor fusion: Conversion of techniques from medical imaging to Earth science

Hughes Aircraft Company and the University of Chicago propose to transfer existing medical imaging registration algorithms to the area of multi-sensor data fusion. The University of Chicago's algorithms have been successfully demonstrated to provide pixel by pixel comparison capability for medical sensors with different characteristics. The research will attempt to fuse GOES (Geostationary Operational Environmental Satellite), AVHRR (Advanced Very High Resolution Radiometer), and SSM/I (Special Sensor Microwave Imager) sensor data which will benefit a wide range of researchers. The algorithms will utilize data visualization and algorithm development tools created by Hughes in its EOSDIS (Earth Observation SystemData/Information System) prototyping. This will maximize the work on the fusion algorithms since support software (e.g. input/output routines) will already exist. The research will produce a portable software library with documentation for use by other researchers.

Savage, Richard C.↗

DOE OSTI2025

REFRACTORY COMPACT HEAT EXCHANGERS WITH EMBEDDED SENSORS ENABLED BY HYBRID ADVANCED SINTERING AND ADDITIVE APPROACH

Structural health monitoring (SHM) of compact heat exchangers (CHXs) operating in extreme environments is essential for ensuring system reliability, safety, and longevity. This study presents the development of high-temperature sensors fabricated via aerosol jet printing (AJP) using platinum ink, selected for its exceptional thermal stability, oxidation resistance, and electrical conductivity. AJP enables precise deposition of fine-feature sensor patterns onto complex geometries, making it well-suited for integration within CHX architectures. To enhance sensor durability, an alumina-based ceramic protective layer was printed over the platinum sensing elements. The sensors demonstrated stable, repeatable performance up to 900?°C during extended thermal cycling. A custom test setup was developed to evaluate sensor accuracy and robustness under steady-state and transient conditions. Substrate screening identified HG-1 ceramic-coated stainless steel as the most effective platform, offering strong adhesion and low resistance. Furthermore, electric field-assisted sintering (EFAS) was employed to embed the sensors into stainless steel 316L matrices without degrading their functionality. Post-embedding electrical tests confirmed sensor integrity, and initial characterization suggests strong potential for in-situ monitoring. This work provides a scalable strategy for integrating high-performance temperature sensors directly into refractory components, advancing embedded SHM technologies for harsh operating environments.

36 - MATERIALS SCIENCE↗

NASA NTRS2009

Proximity Operations and Docking Sensor Development

The Next Generation Advanced Video Guidance Sensor (NGAVGS) has been under development for the last three years as a long-range proximity operations and docking sensor for use in an Automated Rendezvous and Docking (AR&D) system. The first autonomous rendezvous and docking in the history of the U.S. Space Program was successfully accomplished by Orbital Express, using the Advanced Video Guidance Sensor (AVGS) as the primary docking sensor. That flight proved that the United States now has a mature and flight proven sensor technology for supporting Crew Exploration Vehicles (CEV) and Commercial Orbital Transport Systems (COTS) Automated Rendezvous and Docking (AR&D). NASA video sensors have worked well in the past: the AVGS used on the Demonstration of Autonomous Rendezvous Technology (DART) mission operated successfully in spot mode out to 2 km, and the first generation rendezvous and docking sensor, the Video Guidance Sensor (VGS), was developed and successfully flown on Space Shuttle flights in 1997 and 1998. 12 Parts obsolescence issues prevent the construction of more AVGS units, and the next generation sensor was updated to allow it to support the CEV and COTS programs. The flight proven AR&D sensor has been redesigned to update parts and add additional capabilities for CEV and COTS with the development of the Next Generation AVGS at the Marshall Space Flight Center. The obsolete imager and processor are being replaced with new radiation tolerant parts. In addition, new capabilities include greater sensor range, auto ranging capability, and real-time video output. This paper presents some sensor hardware trades, use of highly integrated laser components, and addresses the needs of future vehicles that may rendezvous and dock with the International Space Station (ISS) and other Constellation vehicles. It also discusses approaches for upgrading AVGS to address parts obsolescence, and concepts for minimizing the sensor footprint, weight, and power requirements. In addition, the testing of the brassboard and proto-type NGAVGS units will be discussed along with the use of the NGAVGS as a proximity operations and docking sensor.

Howard, Richard T.↗

NASA NTRS1994

Ultra Low Power Imaging Systems Using CMOS Image Sensor Technology

The need for miniaturization in advanced science sensor systems has led to the development of a new image sensor technology, the active pixel image sensor (APS). The development of CMOS APS technology allows the integration of timing and control electronics, imaging detector arrays, signal chains and analog-to-digital conversion on a single integrated circuit. The impact on the imaging system is to reduce power by approximately 1000x over existing systems - from tens of watts to tens of milliwatts.

imaging↗

DOE OSTI2024

3D Integrated Sensing Solutions

We will present the proposed research project to develop 3D-integrated sensors using advanced manufacturing capability for novel sensors, heterogeneously integrated with energy efficient readout circuits. The lack of precision timing in particle tracking detectors and the absence of low power, high throughput communications solutions to read them out limits progress in multiple fields of fundamental science. The aim of the project is to develop technology to enable large-scale particle detectors with 3D-integrated ASIC designs to simultaneously achieve 10 μm position resolution and 10 ps precision timing, with low-power consumption and high throughput rates. This research program leverages the unique combination of facilities and cross-disciplinary expertise of scientists and engineers at SLAC, FNAL, and LLNL and industrial partners.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

NASA NTRS2006

Effects of Optical Artifacts in a Laser-Based Spacecraft Navigation Sensor

Testing of the Advanced Video Guidance Sensor (AVGS) used for proximity operations navigation on the Orbital Express ASTRO spacecraft exposed several unanticipated imaging system artifacts and aberrations that required correction to meet critical navigation performance requirements. Mitigation actions are described for a number of system error sources, including lens aberration, optical train misalignment, laser speckle, target image defects, and detector nonlinearity/noise characteristics. Sensor test requirements and protocols are described, along with a summary of test results from sensor confidence tests and system performance testing.

LeCroy, Jerry E.↗

NASA NTRS2007

Effects of Optical Artifacts in a Laser-Based Spacecraft Navigation Sensor

LeCroy, Jerry E.↗

NASA NTRS2007

Effects of Optical Artifacts in a Laser-Based Spacecraft Navigation Sensor

Testing Of the Advanced Video Guidance Sensor (AVGS) used for proximity operations navigation on the Orbital Express ASTRO spacecraft exposed several unanticipated imaging system artifacts and aberrations that required correction, to meet critical navigation performance requirements. Mitigation actions are described for a number of system error sources, including lens aberration, optical train misalignment, laser speckle, target image defects, and detector nonlinearity/noise characteristics. Sensor test requirements and protocols are described, along with a summary ,of test results from sensor confidence tests and system performance testing.

LeCroy, Jerry E.↗

NASA NTRS1988

Development of sensors for ceramic components in advanced propulsion systems: Survey and evaluation of measurement techniques for temperature, strain and heat flux for ceramic components in advanced propulsion systems

The report presents the final results of Tasks 1 and 2, Development of Sensors for Ceramic Components in Advanced Propulsion Systems (NASA program NAS3-25141). During Task 1, an extensive survey was conducted of sensor concepts which have the potential for measuring surface temperature, strain and heat flux on ceramic components for advanced propulsion systems. Each sensor concept was analyzed and evaluated under Task 2; sensor concepts were then recommended for further development. For temperature measurement, both pyrometry and thermographic phosphors are recommended for measurements up to and beyond the melting point of ceramic materials. For lower temperature test programs, the thin-film techniques offer advantages in the installation of temperature sensors. Optical strain measurement techniques are recommended because they offer the possibility of being useful at very high temperature levels. Techniques for the measurement of heat flux are recommended for development based on both a surface mounted sensor and the measurement of the temperature differential across a portion of a ceramic component or metallic substrate.

Atkinson, W. H.↗

NASA NTRS1986

Solid state imagers and their applications; Proceedings of the Meeting, Cannes, France, November 26, 27, 1985

Topics treated include the use of semiconductor imagers in high energy particle physics, an X-ray image sensor based on an optical TDI-CCD imager, and an electron-sensitive CCD readout array for a circular-scan streak tube. Papers are presented on the pan-imager, high resolution linear arrays, the reduction of reflection losses in solid-state image sensors, a high resolution CCD imager module with swing operation, large area CCD image sensors for scientific applications, and new readout techniques for frame transfer CCDs. Consideration is given to advanced optoelectronical sensors for autonomous rendezvous/docking and proximity operations in space, the testing and characterization of CCDs for the Rosat star sensors, an advanced radial camera for the Hubble Space Telescope, and scanning or staring infrared imagers.

Declerck, Gilbert J.↗

DOE OSTI2022

Recent Advances in 3D Printed Sensors: Materials, Design, and Manufacturing

Sensors are of great importance in different aspects of research and industry. Future sensors will require high-efficient and low-cost manufacturing, as well as high-performance functionality in areas, such as mechanical sensing, biomedical, and optical applications. Recent advances in 3D printing open a new paradigm for sensors fabrication as a precision, customizable, and seamless process. Here, in this article, the state-of-the-art 3D printing methods in sensors manufacturing is reviewed and the performance of the 3D printed sensing materials and devices is summarized. Special attention is paid to emerging multimaterial printing and 4D printing technologies, which will benefit the fabrication of a new generation of structures with multifunctionalities. The content on 3D printed sensors covers piezoelectric sensors, medical, and optical sensing devices. The performance of 3D printed sensors in comparison with the sensors made by traditional manufacturing is also covered. Finally, section 4 provides the viewpoints on the future development of 3D printed sensors.

36 MATERIALS SCIENCE↗

NASA NTRS2005

Hydrogen Sensors Boost Hybrids; Today's Models Losing Gas?

Advanced chemical sensors are used in aeronautic and space applications to provide safety monitoring, emission monitoring, and fire detection. In order to fully do their jobs, these sensors must be able to operate in a range of environments. NASA has developed sensor technologies addressing these needs with the intent of improving safety, optimizing combustion efficiencies, and controlling emissions. On the ground, the chemical sensors were developed by NASA engineers to detect potential hydrogen leaks during Space Shuttle launch operations. The Space Shuttle uses a combination of hydrogen and oxygen as fuel for its main engines. Liquid hydrogen is pumped to the external tank from a storage tank located several hundred feet away. Any hydrogen leak could potentially result in a hydrogen fire, which is invisible to the naked eye. It is important to detect the presence of a hydrogen fire in order to prevent a major accident. In the air, the same hydrogen-leak dangers are present. Stress and temperature changes can cause tiny cracks or holes to form in the tubes that line the Space Shuttle s main engine nozzle. Such defects could allow the hydrogen that is pumped through the nozzle during firing to escape. Responding to the challenges associated with pinpointing hydrogen leaks, NASA endeavored to improve propellant leak-detection capabilities during assembly, pre-launch operations, and flight. The objective was to reduce the operational cost of assembling and maintaining hydrogen delivery systems with automated detection systems. In particular, efforts have been focused on developing an automated hydrogen leak-detection system using multiple, networked hydrogen sensors that are operable in harsh conditions.

Source record↗

DOE OSTI2026

High-Accuracy and High-Stability Fiber-Optic Temperature Sensors for Coal Fired Advanced Energy

A research team at Michigan State University, led by Dr. Ming Han, has developed a revolutionary fiber-optic thermometer for use in next-generation coal-fired power plants. Funded by the U.S. Department of Energy, this new sensor is designed to measure extremely high temperatures with unmatched accuracy and long-term stability. Unlike conventional optical sensors that can give false readings due to mechanical strain and often drift out of calibration at high heat, this new technology uses a sealed gas chamber as its core. By measuring the temperature-dependent properties of the gas (air or argon), the sensor’s readings remain absolute and reliable, completely unaffected by the physical stresses on the surrounding equipment. The breakthrough design eliminates the need for complex and costly correction systems. It represents a fundamental shift in sensing technology, paving the way for a primary thermometer that maintains calibration and provides foundational accuracy essential for advanced energy systems.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2022

Development and testing of a performance evaluation methodology to assess the reliability of occupancy sensor systems in residential buildings

With the emergence of advanced occupancy sensor technologies to better detect occupancy in buildings, a universal methodology and metrics are required to evaluate and report sensor systems’ reliability and compare the performance across multiple sensor systems. Herein this research presents a methodology to assess the reliability of occupancy sensor systems in residential buildings in a controlled laboratory environment, including both “typical” and “failure” testing scenarios. The developed methodology was then implemented to evaluate a novel occupancy detection sensor system’s reliability. “Typical” testing evaluates the overall accuracy of the sensor system, which suggest how reliable the occupancy sensor system is over time. Results show that on average, the precision and recall are 0.75 and 0.70, indicating similar numbers of false positives and false negatives across the dataset. The overall accuracy of the tested sensor system was 62.4% to 76.4%. Failure testing results indicate whether there are influential variables impacting the sensor performance. For the tested sensor system, the number of occupants, presence of large objects, presence of interior light sources, and number of doors are not influential, while lighting level, location of occupants, additional door in the entry/exit area, and having the TV on are variables determined to impact the sensor system performance.

47 OTHER INSTRUMENTATION↗

NASA NTRS1974

A strapdown laser gyro navigator

A broad spectrum of commercial and military vehicles employ some form of inertial measurement equipment. In general this equipment has a special purpose in that it was tailored for each specific application thereby resulting in high installation and maintenance costs. Recently the emphasis has been directed toward developing low cost building blocks from which the desired inertial functions can be derived. This paper describes a National Aeronautics and Space Administration (NASA) program that combines inertial system sensor and computational advances into a flight demonstration configuration. Specifically, an inertial navigation system employing strapdown laser gyro angular rate sensors and a miniature, modular digital flight computer is described. The objective of this program is to demonstrate, via flight test evaluation, the capabilities of the advanced sensor and computer as they apply to future low cost, high reliability inertial system applications.

Garret, H.↗

DOE OSTI2026

Advancing Industry 4.0: Multimodal Sensor Fusion for AI-Based Fault Detection in 3D Printing

Additive manufacturing, particularly fused deposition modeling, is transforming modern production by enabling rapid prototyping and complex part fabrication. However, its layer-by-layer process remains vulnerable to faults such as nozzle clogging, filament runout, and layer misalignment, which compromise print quality and reliability. Traditional inspection methods are costly, time-intensive, and often limited to post-process analysis, making them unsuitable for real-time intervention. In this current study, the authors developed a novel, low-cost, and portable faultdetection system that leverages multimodal sensor fusion and artificial intelligence for real-time monitoring in FDM-based 3D printing. The system integrates acoustic, vibration, and thermal sensing into a non-intrusive architecture, capturing complementary data streams that reflect both mechanical and process-related anomalies. Acoustic and thermal sensors operate in a fully contactless manner, while the vibration sensor requires minimal attachment such that it will not interfere with printer hardware, thereby preserving portability and ease of deployment. The multimodal signals are processed into spectrograms and time-frequency features, which are classified using convolutional neural networks for intelligent fault detection. The proposed system advances Industry 4.0 objectives by offering an affordable, scalable, and practical monitoring solution that improves faultdetection accuracy, reduces waste, and supports sustainable, adaptive manufacturing.

42 ENGINEERING↗