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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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Nondestructive ultrasonic characterization of a triple-weld-bead wire arc additively manufactured ER70S-6 S-curved wall

Understanding build-scale microstructural variation in wire arc additive manufacturing (WAAM) of low-carbon steels is essential for ensuring consistent structure–property relationships throughout large components. Conventional destructive characterization techniques, such as scanning electron microscopy (SEM) and electron backscatter diffraction (EBSD), are time-intensive and limited to localized regions, making comprehensive evaluation of large WAAM structures challenging. In this study, a nondestructive ultrasonic approach was employed to characterize a 252 mm tall ER70S-6 S-curved WAAM wall produced using a triple-bead deposition strategy. Optical and SEM analysis revealed a repeating dual-region microstructure consisting of uniform polygonal ferrite at melt pool centers and heterogeneous ferrite with coarse and fine grains near melt pool boundaries, attributed to cyclic thermal conditions. Longitudinal ultrasonic backscatter imaging was used to evaluate the continuity of this periodicity along the full build height. The ultrasonic response exhibited a consistent repeating pattern that correlated with the observed layer-wise microstructural variation. X-ray computed tomography confirmed the absence of detectable porosity, indicating that ultrasonic contrast is primarily governed by grain morphology. Overall, the results indicate that longitudinal backscatter ultrasound is a promising nondestructive characterization technique for validating microstructural variations along the s-curved WAAM wall, with significant potential for microstructure optimization and process control.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Advanced Materials and Manufacturing Technologies Nondestructive Examination Efforts at Idaho National Laboratory: Report of FY-24 Efforts

This report details FY-24 nondestructive examination (NDE) efforts at Idaho National Laboratory (INL) in support of the Advanced Materials and Manufacturing Technologies (AMMT) program. While the goal of this endeavor is to develop a multi-modal, multi-length scale workflow for nondestructive characterization of advanced manufactured (AM) nuclear reactor components, substantial development remains until this is a reality. In support of this effort X-ray computed tomography (XCT), X-ray diffraction (XRD), neutron computed tomography (nCT), neutron diffraction, lock-in thermography (LIT), multi-point lock-in thermography (MLIT), and positron annihilation spectroscopy (PAS) were all used on AM specimens to examine defects such as voids, porosity, and residual stress. In addition to summarizing the results of these NDE applications, recommendations for integrating these into a more comprehensive undertaking to promote NDE of engineering-scale components are also included.

36 MATERIALS SCIENCE↗
NASA NTRS2022

Guidebook for the Design and Analysis of a NASA Standard Nondestructive Evaluation (NDE) Probability of Detection (POD) Study

Purpose: This document provides guidance on the design and analysis of a NASA Standard nondestructive evaluation (NDE) probability of detection (POD) study. A Standard NDE flaw size is considered to be conservative such that most inspectors, trained and certified in the specific NDE method, are expected to provide at least 90/95 POD for that flaw size to inspect fracture-critical hardware. Scope: This document is specifically applicable to NASA Technical Standards that establish the NDE requirements for any NASA system or component, flight or ground, where fracture control and a quantitative demonstration of POD is a requirement, including NASA-STD-5009B, Nondestructive Evaluation Requirements for Fracture-Critical Metallic Components, and NASA-STD-5019A,Fracture Control Requirements for Spaceflight Hardware.

Probability of Detection↗
DOE OSTI2021

Improved Nondestructive Isotopic Analysis with Practical Microcalorimeter Gamma Spectrometers

Advances in both instrumentation and data analysis software are now enabling the first ultra-high-resolution microcalorimeter gamma spectrometers designed for implementation in nuclear facilities and analytical laboratories. With approximately ten times better energy resolution than high-purity germanium detectors, these instruments can overcome important uncertainty limits. Microcalorimeter gamma spectroscopy is intended to provide nondestructive isotopic analysis capabilities with sufficient precision and accuracy to reduce the need for sampling, chemical separations, and mass spectrometry to meet safeguards and security goals. Key milestones were the development of the SOFIA instrument (Spectrometer Optimized for Facility Integrated Applications) and the SAPPY software (Spectral Analysis Program in PYthon). SOFIA is a compact instrument that combines advances in large multiplexed transition-edge sensor arrays with optimized cryogenic performance to overcome many practical limitations of previous systems. With a 256-pixel multiplexed detector array capable of 5,000 counts per second, measurement time can be comparable to high-purity germanium detectors. SAPPY was developed to determine isotopic ratios in data from SOFIA and other microcalorimeter instruments with an approach similar to the widely-used FRAM software. SAPPY provides a flexible framework with rigorous uncertainty analysis for both microcalorimeter and high purity germanium (HPGe) data, allowing direct comparison. Here, we present current results from the SOFIA instrument, preliminary isotopic analysis using SAPPY, and describe how the technology is being used to explore uncertainty limits of nondestructive isotopic characterization, inform safeguards models, and extract improved nuclear data including gamma-ray branching ratios.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2024

Nondestructive geochemical characterization of fossil hominin taphonomy and burial history

To date, only three Homo habilis specimens have been discovered that have associated craniodental and postcranial elements, providing a limited fossil record of the ontogeny and morphology of early members of the genus Homo. Recently, a nearly complete dentition, likely attributable to H. habilis, was discovered and excavated from early Pleistocene-age fluvial-lacustrine sediments of the upper Burgi Member of the Koobi Fora Formation at site F25787 in Area 13, near Ileret, Kenya. On the surface less than 15 m away, at site F25966, postcranial elements were found, which, if from the same individual as the nearby dentition, would represent the fourth associated craniodental and postcranial assemblage of this species. We developed a geochemical taphonomic history of these ca. 2 Ma hominin fossils using nondestructive X-ray based microanalytical tools (synchrotron and benchtop X-ray fluorescence chemical imaging and micro- and nano-computed tomography volumetric reconstruction), bulk analyses of sediments and paleosols at the excavation sites, and sedimentologic and stratigraphic observations. We integrate the chemical and physical taphonomic histories to test whether teeth (excavated in situ) and postcranial bones (eroded onto the outcrop surface) derive from a single individual. Minor differences in taphonomic history are attributable to the different biomineral properties of the dental and osseous components and to differences in physical damage during early post-mortem scavenging, dispersal, and burial in adjacent depositional settings. Microscale geochemical mapping enabled the temporal ordination of chemical and physical events in the specimens’ chemical taphonomic histories. Specifically, authigenic Fe- and K-bearing clays and Y, U, and Sr uptake occurred in post-burial fractures in bones and were also incorporated pervasively throughout dentin in teeth. Barite mineralization occurred along the latest fractures in both materials, and as a coating on tooth roots. The stratigraphic, taphonomic, and geochemical evidence supports the interpretation that the hominin fossils represent a single individual. Finally, successful application of these nondestructive sample characterization methods demonstrates capabilities for thorough interrogation of the taphonomic histories of other potential hominin fossil associations, enabling more robust and accurate palaeontologic constraints using those relationships.

36 MATERIALS SCIENCE↗
DOE OSTI2024

A Review of Remote Welding and Nondestructive Examination Technologies for the DOE Standard Canister

The U.S. Department of Energy (DOE) manages a wide variety of spent nuclear fuel (SNF) that poses a unique management challenge. To help address this challenge, the DOE Standard Canister (DOESC), designed to remain sealed during handling, storage, transportation, and disposal, was conceptualized as a standardized containment vessel to accommodate DOE-managed SNF. Since 1999, several welding and examination processes have been independently developed for the DOESC’s closure welds. However, neither the DOESC nor these processes have been realized in an operational capacity. This review paper seeks to present and compare previously developed DOESC closure weld, nondestructive examination, and repair processes and technologies. Specific processes developed for the Idaho Spent Fuel Facility, in preparation for the Yucca Mountain geological repository, and the recent Road-Ready Demonstration Project are discussed. Further, specific focus is given to how different operating constraints and the American Society of Mechanical Engineers Boiler and Pressure Vessel Code (BPVC) have driven certain welding and nondestructive examination requirements. Historical DOESC welding and examination strategies are assessed against current regulatory and BPVC requirements. The comparison of welding processes, technologies, and DOESC designs presented in this review paper will inform further construction efforts for other commercial and DOE-managed SNF containments, including the DOESC.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2023

Passive and active neutron signatures of 233 U for nondestructive assay

The thorium fuel cycle is emerging as an attractive alternative to conventional nuclear fuel cycles, as it does not require the enrichment of uranium for long-term sustainability. The operating principle of this fuel cycle is the irradiation of 232 Th to produce 233 U, which is fissile and sustains the fission chain reaction. 233 U poses unique challenges for nuclear safeguards, as it is associated with a uniquely extreme γ-ray environment from 232 U contamination, which limits the feasibility of the γ-ray-based assay, as well as more conservative accountability requirements than for 235 U set by the International Atomic Energy Agency. Consequently, instrumentation used for safeguarding 235 U in traditional fuel cycles may be inapplicable. It is essential that the nondestructive signatures of 233 U be characterized so that nuclear safeguards can be applied to thorium fuel-cycle facilities as they come online. In this work, a set of 233 U 3 O 8 plates, containing 984 g 233 U, was measured at the National Criticality Experiments Research Center. A high-pressure 4 He gaseous scintillation detector, which is insensitive to γ-rays, was used to perform a passive fast neutron spectral signature measurement of 233 U 3 O 8 , and was used in conjunction with a pulsed deuterium-tritium neutron generator to demonstrate the differential die-away signature of this material. Furthermore, an array of 3 He detectors was used in conjunction with the same neutron generator to measure the delayed neutron time profile of 233 U, which is unique to this nuclide. These measurements provide a benchmark for future nondestructive assay instrumentation development, and demonstrate a set of key neutron signatures to be leveraged for nuclear safeguards in the thorium fuel cycle.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2021

Nondestructive Characterization of Antireflective Coatings on PV Modules

Antireflective coatings (ARCs) are used on the vast majority of solar photovoltaic (PV) modules to increase power production. However, ARC longevity can vary from less than 1 to over 15 years depending on coating quality and deployment conditions. A technique that can quantify ARC degradation nondestructively on commercial modules would be useful both for in-field diagnostics and accelerated aging tests. In this article, we demonstrate that accurate measurements of ARC spectral reflectance can be performed using a modified commercially available integrating-sphere probe. The measurement is fast, accurate, nondestructive, and can be performed outdoors in full-sun conditions. We develop an interferometric model that estimates coating porosity, thickness, and fractional area coverage from the measured reflectance spectrum for a uniform single-layer coating. We demonstrate the measurement outdoors on an active PV installation, identify the presence of an ARC, and estimate the properties of the coating.

14 SOLAR ENERGY↗
DOE OSTI2020

Development of Thermal Tomography Imaging System for In-Service Nondestructive Evaluation of Additively Manufactured Components

Additive manufacturing (AM) is an emerging method for cost-efficient fabrication of nuclear reactor parts. AM of metallic structures for nuclear energy applications is currently based on laser powder bed fusion (LPBF) process, which can introduce internal material flaws, such as pores and anisotropy. Integrity of AM structures needs to be evaluated nondestructively because material flaws could lead to premature failures due to exposure to high temperature, radiation and corrosive environment in a nuclear reactor. Thermal tomography (TT) provides a capability for non-destructive evaluation of sub-surface defects in arbitrary size structures. We investigate TT of AM stainless steel 316L specimen with imprinted internal porosity defects using relatively low-cost, small form factor infrared (IR) camera based on uncooled micro bolometer detector. Sparse coding related K-means singular value decomposition (SVD) machine learning, image processing algorithms are developed to improve quality of TT images through removal of Additive white Gaussian noise without blurring the images. Following initial qualification of an AM component for deployment in a nuclear reactor, a compact TT can also be used for in-service nondestructive evaluation (NDE). With capability to perform in-service NDE of the AM component lifecycle, TT data can be used for development of a component digital twin. MIT research reactor (MITR) has been identified as a representative environment to perform investigation of feasibility of in-service NDE during shutdown. Preliminary study of radiation level in the MITR viewport, with geometric parameters potentially compatible with compact TT system, has been conducted.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Characteristics of Uranium-Plutonium Mixed Oxide Nondestructive Assay Standards

A set of six well-characterized, homogeneous, mixed HEU-WGPu oxide standards has been manufactured for and are proposed for qualification as NDA working reference standards with SAFE-NMCA. These standards, if approved, will provide the basis for qualifying the FRAM isotopic systems for use in accountability measurements of 235U in the presence of Pu for unknown mixed U-Pu items by nondestructive assay. The U to Pu elemental mass ratios of the six analytical standards are nominally in the proportions 0.1, 0.25, 1.0, 2.5, 10, and 20; these values were chosen to span the U/Pu mass ratios of inventory items that ultimately will be measured by nondestructive assay and which currently reside in long term storage. The measured characteristics, including plutonium and uranium elemental masses and isotopic distribution, of each standard and relevant source documentation are reported here.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Modeling Nondestructive Defect Detection in Additively Manufactured Metallic Structures for Nuclear Applications

The future of quickly, economically produced metallic nuclear reactor parts with minimal supply-chain dependence lies in Laser Powder Bed Fusion (LPBF) Additive Manufacturing (AM): a 3D printing method involving laser melting and net shaping stainless steel and Inconel metallic powder into a solid structure. However, intrinsic features in LPBF frequently leads to the formation of materials defects, such as pores, within 3D printed structures. As safe long-term use in energy applications requires knowledge of all relevant defects before deployment in a reactor, we must develop methods for nondestructive detection of these defects. We are investigating Pulsed Thermal Tomography (PTT), which is a non-contact nondestructive imaging method scalable to arbitrary structure size. Thermal tomography (TT) is a computational method for 3D spatial reconstruction of material thermal effusivity from flash or pulsed thermography temperature data cube. Thermography data cube consists of 2D surface temperature measurements at different times. The objective of the present work is to investigate limits on defect detection in AM metallic structures with PTT. To this effect, we modeled PTT with COMSOL heat transfer computer simulations. We developed a layered media COMSOL simulation consisting of a Stainless Steel 316 (SS316) plate with an internal layer of un-sintered SS316 powder. Thermophysical properties of the powder layer were modeled with equivalent volume mixing model. To account for partial sintering at the boundary of the defect, the transition between solid and powder layers was modeled as a Gaussian. Using data from COMSOL simulations, we reconstructed depth-dependent thermal effusivity, which allowed defect visibility estimation. A series of parametric studies determined that at 1mm depth, 50µm is the smallest detectable defect. In addition, classification of the defects which can lead to early fatigue of the metallic structure in a reactor is briefly discussed.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Pulsed Thermal Tomography Nondestructive Examination of Additively Manufactured Reactor Materials and Components (Final Technical Report)

Metal Additive Manufacturing (AM) is a promising method for cost-efficient fabrication of complex shape structures for applications in harsh environment, such as in a nuclear reactor. However, internal defects (pores) occur in high-strength AM alloys, which are manufactured with Laser Powder Bed Fusion (LPBF) AM method. Pulsed Infrared Thermography (PIT) is an efficient nondestructive evaluation (NDE) method to examine actual structures, because this method offers one-sided non-contact measurements, and fast processing of large sample areas. However, imaging of material defects, particularly defects with sizes at microscopic level, is challenging. In this report, we benchmark the performance of several Unsupervised Learning (UL) algorithms designed to enhance imaging of microscopic defects in metals with PIT. UL aims to learn the latent principal patterns (dictionaries) in PIT data to detect defects with minimal human supervision. Performance of Independent Component Analysis (ICA), Sparse Coding (SC), Principal Component Analysis (PCA) and Exploratory Factor Analysis (EFA) was compared using F-score, UL model training time and defects reconstruction time. We obtained the average F-score of 0.75, and a highest F-score of 0.89 for the EFA algorithm. Overall, EFA outperforms other UL algorithms considered in this study. In another approach, we investigate Thermal Tomography (TT), which is a computational method for reconstruction of depth profile of internal material defects from PIT nondestructive evaluation (NDE). TT algorithm obtains depth reconstructions of thermal effusivity, which has been shown to provide visualization of subsurface internals defects in metals. In many applications, one needs to determine the defect shape and orientation from reconstructed effusivity images. Interpretation of TT images is non-trivial because of blurring, which increases with depth due to heat diffusion-based nature of image formation. We have developed a deep learning convolutional neural network (CNN) to classify size and orientation of subsurface material defects in TT images. CNN was trained with TT images produced with computer simulations of 2D metallic structures (thin plates) containing elliptical subsurface voids. Performance of CNN was investigated using test TT images developed with computer simulations of plates containing elliptical defects, and defects with shape imported from scanning electron microscopy (SEM) images. CNN demonstrated the ability to classify radii and angular orientation of elliptical defects in previously unseen test TT images. We have also demonstrated that CNN trained on TT images of elliptical defects is capable of classifying shape and orientation of irregular defects. Training the CNN on irregular defect shapes instead of on elliptical shapes would make the resulting classifications more descriptive of actual defect shapes. However, this requires a much higher volume of SEM images of material defects, which are difficult to obtain because of random occurrence of defects in LPBF. To address this challenge, we developed a generative adversarial network (GAN) to augment the existing dataset of SEM defect images. The GAN model is demonstrated to create novel yet realistic defect shapes that can be used as input for simulated PTT images to train CNN. We also investigate several approaches based on Gaussian Random Circle and Bezier Curves for constructing parametric models of irregular-shape defects.

36 MATERIALS SCIENCE↗
DOE OSTI2023

An Assessment of Machine Learning Applied to Ultrasonic Nondestructive Evaluation

In the United States, the nuclear industry performs inservice inspection (ISI) through nondestructive examination (NDE) methods in accordance with guidelines specified in the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code (BPVC), Section XI, Rules for Inservice Inspection of Nuclear Power Plant Components. Ultrasonic nondestructive testing and evaluation (NDT&E) is one of the more commonly used techniques for inspecting Class 1 structural components in nuclear power systems. As the number of qualified NDE inspectors declines, the nuclear industry is looking to take advantage of advances in automation to enhance inspection capabilities. Advances in computational power, cloud-based computing, and machine learning algorithms make automated data analysis possible. Machine learning (ML) has shown huge potential in automated data analyses for ultrasonic NDE in the context of weld inspections.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS1971

Evaluation of nondestructive tensile testing

The results of a series of experiments performed in the evaluation of nondestructive tensile testing of chip and wire bonds are presented. Semiconductor devices were subjected to time-temperature excursions, static-load life testing and multiple pre-stressing loads to determine the feasibility of a nondestructive tensile testing approach. The report emphasizes the importance of the breaking angle in determining the ultimate tensile strength of a wire bond, a factor not generally recognized nor implemented in such determinations.

Bowe, J. J.↗
NASA NTRS1972

Development of techniques and instrumentation for the nondestructive evaluation of multi-layer insulation

The development of techniques and instrumentation suitable for the nondestructive evaluation of purged multilayer insulation prior to and after a shuttle orbiter flight is discussed. These techniques are desirable because of the possibility that corrosion, compression, or tearing of the insulation will degrade the performance of the insulation during subsequent flights. A second objective was the application of the developed technology to the evaluation of other insulation types. Three nondestructive evaluation techniques, electromagnetic, thermal, and acoustic were selected for evaluation. The results of evaluation of each technique are described.

Source record↗
NASA NTRS1973

Nondestructive testing: Introduction

A comparison of selected nondestructive evaluation methods is presented. The properties sensed, type of flaws detected, and application for each nondestructive test are shown.

C. Gerald Gardner↗
NASA NTRS1974

Guidebook of nondestructive evaluation techniques for materials and structures

Seventy nondestructive techniques for evaluating material and structures are described in guidebook. Standardized format facilitates comparison of their merits and limitations for solving various problems. Guide includes index of flaw types and tabulated guide to use of nondestructive evaluation techniques. Alternative technique names are cross-referenced.

Vary, A.↗