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At least 37 records · Page 2

A Digital Twin Approach to Study Additive Manufacturing Processing Using Embedded Optical Fiber Sensors and Numerical Modeling

One of the major challenges for metal-powder-based additive manufacturing is measuring and mitigating residual strain induced during the manufacturing processes. This article reports distributed fiber optic sensors embedded in Inconel alloy components as experimental means to validate numerical models of additive manufacturing process. Electroplating was used to deposit a metal protective jacket onto standard telecom single-mode fibers for strain measurements, Fiber sensors were embedded in an Inconel alloy substrate using the laser engineered net shaping (LENS) process. Here by using a Rayleigh-scattering optical frequency domain reflectometer (OFDR), temperature changes, and residual strain in the metal substrate were monitored with 5 mm spatial resolution during the LENS process. Using finite element analysis, temperature and strain profiles induced by the LENS deposition processes were also numerically studied. Discrepancies between the simulated temperature and strain profiles and those measured directly were less than 10%. Results presented in this article demonstrates a digital twin approach to fuse modeling results with distributed fiber sensor measurement data to study additive manufacturing process toward design and fabrication process optimization.

36 MATERIALS SCIENCE↗

Active control for vibration suppression in a flexible beam using a modal domain optical fiber sensor

An account is given of the use of a modal-domain (MD) fiber-optic sensor as an active control system component for vibration suppression, whose output is proportional to the integral of the axial strain along the optical fiber. When an MD sensor is attached to, or embedded in, a flexible structure, it senses the strain in the structure along its gage length. On the basis of the present integration of the sensor model into a flexible-structure model, it becomes possible to design a control system with a dynamic compensator which adds damping to the low-order modes of the flexible structure. This modeling procedure has been experimentally validated.

Cox, D. E.↗

Metal-embedded fiber optic sensor packaging and signal demodulation scheme towards high-frequency dynamic measurements in harsh environments

Optical fiber-based sensors are commonly used for industrial monitoring and control processes due to their small size, resistance to electromagnetic interference, and ability to perform a wide variety of high-precision measurements. However, implementing optical fiber sensors in harsh environments is challenging because they are small and fragile. Proper packaging of fiber-optic sensors could extend their use to harsh environments, including at high temperature and under high radiation. Furthermore, conventional fiber optic-based measurement systems often use computationally expensive signal processing algorithms which hinder their use in high-frequency dynamic applications. This work reports on the design of an optical fiber-pressure sensor system based on low-coherence interferometry that uses a metal-embedded optical fiber to provide a robust sensor package. Additionally, a novel phase demodulation scheme is proposed to extract length changes from the deformation of a thin diaphragm within a Fabry–Pérot cavity to measure pressure. The sensor has been tested to ±100 kPa, has a theoretical linear response over a 270 kPa dynamic range (24 dB maximum signal-to-noise ratio), and can resolve pressure transients up to 3910 kPa/s. Sampling at 100 kHz, the present sensor can resolve 2 kPa dynamic pressures at frequencies up to 2 kHz. Faster transients on the order of tens to hundreds of kHz can theoretically be resolved at the expense of decreasing the maximum resolvable amplitude. A methodology for designing a LCI pressure sensor for a given application is outlined based on the limitations imposed by the Nyquist criterion, the diaphragm's resonant frequency, the LCI optoelectronics, and the phase demodulation scheme. The sensor is the first to implement a low-coherence light source and a Fabry–Pérot interferometer designed to provide real-time high-fidelity pressure measurements using a metal-embedded optical fiber. The demonstrated sensor provides a platform for sensing in harsh conditions such as in nuclear and energy applications.

47 OTHER INSTRUMENTATION↗

Optical Fiber Sensor Technology Development and Field Validation for Distribution Transformer and Other Grid Asset Health Monitoring

Power transformers are critical pieces of infrastructure in the electric grid that are both extremely expensive and difficult to replace. These transformers often have long lead times for replacement, and failures can create long service disruptions. This project has developed a new suite of sensors designed to give early warning of the impending failure of these important power transformers before it is too late and a major failure occurs. By using novel fiber optic sensors instead of conventional existing technologies, we are able to measure transformer characteristics indicative of impending failures in ways that were not previously possible. These new optical fiber-based sensors are completely immune to the strong magnetic fields present in power transformers, as well as being capable of using distributed measurement techniques. Distributed measurement techniques enable the fiber to return information all along its length as opposed to only collecting data at a single point; as would a thermocouple or standard pressure sensor.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Fiber Optic Sensors for Health Monitoring of Morphing Aircraft

Fiber optic sensors are being developed for health monitoring of future aircraft. Aircraft health monitoring involves the use of strain, temperature, vibration and chemical sensors. These sensors will measure load and vibration signatures that will be used to infer structural integrity. Sine the aircraft morphing program assumes that future aircraft will be aerodynamically reconfigurable there is also a requirement for pressure, flow and shape sensors. In some cases a single fiber may be used for measuring several different parameters. The objective of the current program is to develop techniques for using optical fibers to monitor composite cure in real time during manufacture and to monitor in-service structural integrity of the composite structure. Graphite-epoxy panels were fabricated with integrated optical fibers of various types. The panels were mechanically and thermally tested to evaluate composite strength and sensor durability. Finally the performance of the fiber optic sensors was determined. Experimental results are presented evaluating the performance of embedded and surface mounted optical fibers for measuring strain, temperature and chemical composition. The performance of the fiber optic sensors was determined by direct comparison with results from more conventional instrumentation. The facilities for fabricating optical fiber and associated sensors and methods of demodulating Bragg gratings for strain measurement will be described.

Brown, Timothy↗

Fiber optic sensors IV; Proceedings of the Third European Congress on Optics, The Hague, Netherlands, Mar. 13, 14, 1990

Recent advances in fiber-optic sensor (FOS) technology are examined in reviews and reports. Sections are devoted to components for FOSs, special fibers for FOSs, interferometry, FOS applications, and sensing principles and influence. Particular attention is given to solder glass sealing technology for FOS packaging, the design of optical-fiber current sensors, pressure and temperature effects on beat length in highly birefringent optical fibers, a pressure FOS based on vibrating-quartz-crystal technology, remote sensing of flammable gases using a fluoride-fiber evanescent probe, a displacement sensor with electronically scanned white-light interferometer, the use of multimode laser diodes in low-coherence coupled-cavity interferometry, electronic speckle interferometry compensated for environmentally induced phase noise, a dual-resolution noncontact vibration and displacement sensor based on a two-wavelength source, and fiber optics in composite materials.

Kersten, Ralf T.↗

Overview of Fiber-Optical Sensors

Design, development, and sensitivity of sensors using fiber optics reviewed. State-of-the-art and probable future developments of sensors using fiber optics described in report including references to work in field. Serves to update previously published surveys. Systems incorporating fiber-optic sensors used in medical diagnosis, navigation, robotics, sonar, power industry, and industrial controls.

Depaula, Ramon P.↗

Embedding of Fiber Optic Sensors in Stainless Steel for Sensing in Harsh Environments

Structural health monitoring is critical for components working in harsh environments to assess their safety and integrity. This can be realized with advanced sensors, such as fiber optic sensors, embedded in these components. Recent studies have used ultrasonic consolidation (UC) and laser-based additive manufacturing (AM) techniques to embed fiber optic sensors in metals. However, sensor embedding using these techniques has been challenging, with gaps and voids around the embedded fiber. Successful embedding of fiber optic sensors requires good contact between the fiber and the matrix to eliminate potential gas/liquid leaks in critical systems such as in nuclear and aerospace services. Defect-free fiber/matrix bond is also essential for accurate measurement of parameters of interest, such as temperature and strain. This study developed a novel fiber embedding technique based on electric field-assisted sintering (EFAS). Sapphire optical fibers with diameters of 125 µm and 250 µm were embedded in stainless steel (SS) 316L using EFAS. The embedding was completed by sintering SS 316L powders at a pressure of 50MPa, hold time of 5 min, and temperatures of 1000°C, 1100°C, and 1200°C. Joule heating mechanism during EFAS enabled rapid sintering of the SS 316L powder with resulting sample densities over 99%. Microscopy analysis performed on the cross-sections revealed a defect-free bond between the embedded fiber and SS 316L. The good integrity of the embedded fiber was evidenced by optical transmittance measurement. Optical attenuation of the fiber before and after embedment was examined in the near-infrared region. Scanning electron microscopy was employed to investigate the grain morphology of SS 316L near the embedded fiber. Hardness distribution in the sintered part was also investigated to study the effect of the embedded fiber on the mechanical properties of the as-fabricated component. The results indicated that EFAS was able to embed fiber in SS with good fiber functionality and part quality.

36 - MATERIALS SCIENCE↗

Distributed strain measurement in a rectangular plate using an array of optical fiber sensors

Single mode optical fiber waveguide has been used to determine the two-dimensional strain distribution on a simply supported rectangular plate. Each of the fifty individual fibers in the rectangular grid array attached to one surface of the plate yields a measurement of the strain integrated along the length of that fiber on the specimen. By using similar sensor information from all of the fibers, both the functional form and the amplitude of the distribution may be determined. Limits on the dynamic range and spatial resolution are indicated. Applications in the measurement of internal strain and the monitoring of physically small critical-structural components are suggested.

Claus, R. O.↗

Design of Fiber Optic Sensors for Measuring Hydrodynamic Parameters

The science of optical hydrodynamics involves relating the optical properties to the fluid dynamic properties of a hydrodynamic system. Fiber-optic sensors are being designed for measuring the hydrodynamic parameters of various systems. As a flowing fluid makes an encounter with a flat surface, it forms a boundary layer near this surface. The region between the boundary layer and the flat plate contains information about parameters such as viscosity, compressibility, pressure, density, and velocity. An analytical model has been developed for examining the hydrodynamic parameters near the surface of a fiber-optic sensor. An analysis of the conservation of momentum, the continuity equation and the Navier-Stokes equation for compressible flow were used to develop expressions for the velocity and the density as a function of the distance along the flow and above the surface. When examining the flow near the surface, these expressions are used to estimate the sensitivity required to perform direct optical measurements and to derive the shear force for indirect optical measurements. The derivation of this result permits the incorporation of better design parameters for other fiber-based sensors. Future work includes analyzing the optical parametric designs of fiber-optic sensors, modeling sensors to utilize the parameters for hydrodynamics and applying different mixtures of hydrodynamic flow. Finally, the fabrication of fiber-optic sensors for hydrodynamic flow applications of the type described in this presentation could enhance aerospace, submarine, and medical technology.

Lyons, Donald R.↗

Pilot-Scale Validation of Distributed Optical Fiber Sensors for Underground Pipeline Monitoring

Monitoring parameters such as hoop strain, pressure, and acoustic vibrations is key to detecting potential leaks, intrusions, or structural issues. Distributed optical fiber sensor (DOFS) systems provide a compelling solution for continuous, real-time monitoring over long distances. This paper details the development and pilot-scale implementation of DOFS systems for underground pipeline monitoring, evolving from a proof-of-concept stage. Multiple custom-designed DOFS interrogator units—such as optical frequency-domain reflectometry (OFDR), Brillouin optical time-domain analysis (BOTDA), and multimodal interferometer-based fiber acoustic sensor systems were tested to measure the key parameters, such as hoop strain, pipe pressure, surrounding soil temperature, and acoustic vibrations. The underground product pipeline’s outer diameter is 30 inches, the wall thickness is 1.28 inches, and 3 feet deep from the surface. The fiber deployment strategies and sensing data acquisition methods for these systems are discussed. The results demonstrate the effectiveness of DOFS in detecting hoop strain, temperature changes, and acoustic vibrations, showcasing their potential for real-time monitoring and enhancing pipeline safety. These findings from pilot-scale testing offer valuable insights into advancing pipeline monitoring technologies and improving the reliability of underground pipeline systems.

fiber optic sensors↗

Three-Arm, Self-Referencing Fiber-Optic Sensor

Sensor reading relatively immune to spurious variations in illumination and transmission. No separate reference channel necessary; provides own internal reference. Illumination for sensor provided by pulsed source of light. Pulses of light travel along optical fiber into sensor assembly including two 1 X 3 fiber-optic couplers and three optical fibers. After entering sensor assembly through left coupler, pulse of light split into three fibers. Three fibers have different lengths chosen to delay pulses by different amounts of time in equal increments.

Adamovsky, Grigory↗

Pressure-Driven Fiber-Optic Sensor for Online Corrosion Monitoring

For many industrial applications, corrosion is a life-limiting phenomenon and therefore requires careful consideration and rigorous experimental testing before structural materials can be reliably deployed, particularly in harsh chemical environments. The traditional approach to measuring corrosion requires exposing many samples to the intended environment and then extracting them individually at discrete intervals for postexposure characterization. This approach does not provide a high degree of temporal resolution, nor does it provide any real-time information regarding dynamic changes in corrosion rates. Additionally, developing an online corrosion monitor capable of surviving harsh chemical environments could provide valuable information regarding the structural health of components and changing process conditions that could accelerate corrosion. To this end, a corrosion sensor was developed based on a pressure-driven Fabry-Pérot cavity (FPC). This sensor uses a pressure control system to internally pressurize the FPC formed between the sensor’s housing and a metal-embedded singlemode optical fiber. Simultaneous measurement of the change in FPC length using low-coherence interferometry and the applied pressure enables the calculation of the relative changes in the sensor’s diaphragm thickness due to corrosion on its outer surface. Measurements were made in situ while actively corroding the sensor and were validated against surveillance specimens that were corroded simultaneously. The uncertainties in the measured corrosion were analyzed using error propagation of the uncertainties in the measured pressures and displacements and were found to be <1% of the initial diaphragm thickness.

42 ENGINEERING↗

Testing and Characterization to Develop a Mechanistic Explanation for Unsaturated Drift of Fiber Optic Sensors during High-Dose Irradiation

The primary limitation for any optical fiber-based sensor for nuclear reactor applications is radiation-induced attenuation (RIA) of the transmitted and/or reflected signals. Based on several recent studies, RIA is tolerable for some fused silica optical fibers with the proper choice of sensing wavelength and fiber dopants. For extreme temperature applications (> 1000°C), sapphire optical fibers have been proposed; however, recent optical transmission measurements performed on bulk sapphire samples showed prohibitively large RIA. For some sensors, radiation-induced dimensional changes in the fiber materials can also cause significant drift. Moreover, the drift that was observed in numerous experiments performed in the High Flux Isotope Reactor (HFIR), the Advanced Test Reactor, the Massachusetts Institute of Technology Reactor, and other international facilities far exceeded what would be expected based on compaction of fused silica glass. Clearly, additional work is needed to better understand the origins of both RIA and radiation-induced drift in both silica and sapphire optical fiber-based sensors before these sensors can be reliably deployed for nuclear applications. This work evaluated the underlying mechanisms that may be responsible for RIA and drift in silica and sapphire materials. First, detailed characterization was performed on bulk fused silica glass samples that were previously irradiated to different neutron fluences at different temperatures to better understand the structural changes that drive radiation-induced drift in the absence of coating effects that are discussed later. Results show that the non-monotonic compaction that occurs with increasing neutron fluence continues up to fast neutron fluences approaching 10 22 n/cm 2 , which has important implications for physics-based models that may be used to compensate for the sensor drift. Initial Raman spectroscopy and synchrotron x-ray diffraction provide insights into the nature of the structural changes. Next, detailed characterizations were performed on silica fibers with various coatings that were subjected to several different thermal treatments. The hypothesis is that the coatings convert to carbon-rich materials that compact under irradiation, putting a large compressive strain on the fiber. Out-of-pile testing confirms that both polyimide and acrylate fiber coatings convert to glassy carbon (GC) materials when heated under inert conditions, and the degree of order (i.e., graphitization) increases with increasing temperature. The results provide increasingly strong evidence that the combination of polymeric coatings and inert (or vacuum) conditions render fiber optic sensors susceptible to significant radiation-induced drift that would not otherwise exist in uncoated fibers. Finally, transmission electron microscopy was performed on bulk sapphire samples that were irradiated to two neutron fluences at different temperatures to gain insights into the potential mechanisms driving the prohibitive RIA at higher neutron fluences and temperatures. Contrary to previous hypotheses, results show that scattering from radiation-induced voids cannot explain the observed RIA. Similarly, models for scattering losses from dislocation loops also do not agree with the experimental results. Instead, fitting to the experimental data shows that increased absorption from aluminum vacancy centers is the most likely explanation for the the prohibitively large RIA that was observed at high irradiation temperature and dose. In addition, the voids that formed in these single-crystal samples were found to align along the basal plane (a-axis) as opposed to that seen in previous observations of c-axis alignment in polycrystalline samples, which could have important implications for anisotropic swelling and other phenomena that could affect sensor performance at high neutron fluence.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Testing and Characterization to Develop a Mechanistic Explanation for Unsaturated Drift of Fiber Optic Sensors during High-Dose Irradiation

The primary limitation for any optical fiber-based sensor for nuclear reactor applications is radiation-induced attenuation (RIA) of the transmitted and/or reflected signals. Based on several recent studies, RIA is tolerable for some fused silica optical fibers with the proper choice of sensing wavelength and fiber dopants. For extreme temperature applications (> 1000°C), sapphire optical fibers have been proposed; however, recent optical transmission measurements performed on bulk sapphire samples showed prohibitively large RIA. For some sensors, radiation-induced dimensional changes in the fiber materials can also cause significant drift. Moreover, the drift that was observed in numerous experiments performed in the High Flux Isotope Reactor (HFIR), the Advanced Test Reactor, the Massachusetts Institute of Technology Reactor, and other international facilities far exceeded what would be expected based on compaction of fused silica glass. Clearly, additional work is needed to better understand the origins of both RIA and radiation-induced drift in both silica and sapphire optical fiber-based sensors before these sensors can be reliably deployed for nuclear applications. This work evaluated the underlying mechanisms that may be responsible for RIA and drift in silica and sapphire materials. First, detailed characterization was performed on bulk fused silica glass samples that were previously irradiated to different neutron fluences at different temperatures to better understand the structural changes that drive radiation-induced drift in the absence of coating effects that are discussed later. Results show that the non-monotonic compaction that occurs with increasing neutron fluence continues up to fast neutron fluences approaching 10 22 n/cm 2 , which has important implications for physics-based models that may be used to compensate for the sensor drift. Initial Raman spectroscopy and synchrotron x-ray diffraction provide insights into the nature of the structural changes. Next, detailed characterizations were performed on silica fibers with various coatings that were subjected to several different thermal treatments. The hypothesis is that the coatings convert to carbon-rich materials that compact under irradiation, putting a large compressive strain on the fiber. Out-of-pile testing confirms that both polyimide and acrylate fiber coatings convert to glassy carbon (GC) materials when heated under inert conditions, and the degree of order (i.e., graphitization) increases with increasing temperature. The results provide increasingly strong evidence that the combination of polymeric coatings and inert (or vacuum) conditions render fiber optic sensors susceptible to significant radiation-induced drift that would not otherwise exist in uncoated fibers. Finally, transmission electron microscopy was performed on bulk sapphire samples that were irradiated to two neutron fluences at different temperatures to gain insights into the potential mechanisms driving the prohibitive RIA at higher neutron fluences and temperatures. Contrary to previous hypotheses, results show that scattering from radiation-induced voids cannot explain the observed RIA. Similarly, models for scattering losses from dislocation loops also do not agree with the experimental results. Instead, fitting to the experimental data shows that increased absorption from aluminum vacancy centers is the most likely explanation for the the prohibitively large RIA that was observed at high irradiation temperature and dose. In addition, the voids that formed in these single-crystal samples were found to align along the basal plane (a-axis) as opposed to that seen in previous observations of c-axis alignment in polycrystalline samples, which could have important implications for anisotropic swelling and other phenomena that could affect sensor performance at high neutron fluence.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

The 1994 Fiber Optic Sensors for Aerospace Technology (FOSAT) Workshop

The NASA Lewis Research Center conducted a workshop on fiber optic technology on October 18-20, 1994. The workshop objective was to discuss the future direction of fiber optics and optical sensor research, especially in the aerospace arena. The workshop was separated into four sections: (1) a Systems Section which dealt specifically with top level overall architectures for the aircraft and engine; (2) a Subsystems Section considered the parts and pieces that made up the subsystems of the overall systems; (3) a Sensor/Actuators section considered the status of research on passive optical sensors and optical powered actuators; and (4) Components Section which addressed the interconnects for the optical systems (e.g., optical connectors, optical fibers, etc.). This report contains the minutes of the discussion on the workshop, both in each section and in the plenary sessions. The slides used by a limited number of presenters are also included as presented. No attempt was made to homogenize this report. The view of most of the attendees was: (1) the government must do a better job of disseminating technical information in a more timely fashion; (2) enough work has been done on the components, and system level architecture definition must dictate what work should be done on components; (3) a Photonics Steering Committee should be formed to coordinate the efforts of government and industry in the photonics area, to make sure that programs complimented each other and that technology transferred from one program was used in other programs to the best advantage of the government and industry.

Baumbick, Robert↗

Methods for Continuously Resolving Spectral Shifts in Distributed Optical Fiber Sensors Irradiated to Extreme Neutron Fluence

Optical frequency domain reflectometry (OFDR) is a technique for interrogating distributed optical fiber sensors (DOFS) and involves correlating changes in the Rayleigh backscatter fingerprint for a fiber under test (FUT) with a reference measurement. Recently, under the WIRE-21 experiment sponsored by Nuclear Science User Facilities (NSUF) and performed at the High-Flux Isotope Reactor (HFIR) at Oak Ridge National Laboratory (ORNL), silica optical fibers were irradiated to a fast neutron fluence of 1x10^21 n/cm^2/s at temperatures from 200--400 C. As in the cases of high-temperature and high-strain conditions, such high levels of neutron bombardment result in a highly dynamic RBS that evades analysis with conventional methods. This work describes the further development and application of graphical signal processing techniques applied to OFDR-based distributed optical fiber sensors specifically deployed in in-pile applications. While the signal processing techniques developed in this work are applied to DOFS in nuclear environments, they provide a general framework for the analysis of OFDR measurements and a tangible method to yield higher quality data, without imposing additional hardware requirements.

Sweeney, Dan↗

Chalcogenide Glass-Capped Fiber-Optic Sensor for Real-Time Temperature Monitoring in Extreme Environments

We demonstrate a novel chalcogenide glass (ChG)-capped optical fiber temperature sensor capable of operating within harsh environment. The sensor architecture utilizes the heat-induced phase change (amorphous-to-crystalline) property of ChGs, which rapidly (80–100 ns) changes the optical properties of the material. The sensor response to temperature variation around the phase change of the ChG cap at the tip of the fiber provides abrupt changes in the reflected power intensity. This temperature is indicative of the temperature at the sensing node. We present the sensing performance of six different compositions of ChGs and a method to interpret the temperature profile between 440 °C and 600 °C in real-time using an array structure. The unique radiation-hardness property of ChGs makes the devices compatible with high-temperature and high-radiation environments, such as monitoring the cladding temperature of Light Water (LWR) or Sodium-cooled Fast (SFR) reactors.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗