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WHONDRS River Corridor Sediment and Water Geochemistry and In Situ Sensor Data from Machine-Learning-Informed Sites across the Contiguous United States (v6)
This dataset supports a broader study examining hyporheic zone respiration rates to improve predictive models at a contiguous United States (CONUS) scale. The CONUS-Scale Model-Sample Study (CM) was designed following ICON (integrated, coordinated, open, and networked) principles to facilitate a model-experiment (ModEx) iteration approach, leveraging crowdsourced sampling across the CONUS. New machine learning models were created every month to guide sampling locations. Data from the resulting samples were used to test and rebuild the machine learning models for the next round of sampling guidance. Sampling began in April 2022 and ended in October 2023. In addition to the widely distributed CONUS sites, a more spatially focused sampling occurred in the Yakima River Basin, WA in summer 2022. Data from this more spatially intensive sampling occurred under the label “Second Spatial Study (SSS)” and were also included in the machine learning models. Other data types collected from SSS that were not part of CM were published in a separate data package (https://data.ess-dive.lbl.gov/view/doi:10.15485/1969566). This data package was originally published in February 2023. It was updated in June 2023 (v2; new and modified files); December 2023 (v3; new and modified files); June 2024 (v4; new and modified files); April 2024 (v5; new and modified files); and September 2025 (v6; modified files). See the change history section in the readme for more details. For details on how to navigate data packages generated by this project, see https://data.ess-dive.lbl.gov/portals/PNNLRiverCorridorSFA/About. This dataset is comprised of two folders of field photos and videos, one folder of raw Fourier transform ion cyclotron resonance mass spectrometry (FTICR-MS) data and one main data folder containing (1) file-level metadata; (2) data dictionary; (3) field metadata; (4) readme; (5) international generic sample number (IGSN) mapping file; (6) field protocols; (7) a subfolder with sample data; and (8) a subfolder with sensor data. The sample data subfolder contains (1) surface water and sediment dissolved organic carbon (DOC, measured as non-purgeable organic carbon, NPOC) data and averages; (2) surface water and sediment total nitrogen data and averages; (3) surface water major cations and anions and averages; (4) sediment grain size data; (5) sediment iron (II) data and averages; (6) wet sediment mass, dry sediment mass, water mass, and wet sediment volume in incubation and sediment ICR vials; (7) sediment incubation respiration rate data and averages; (8) normalized respiration rate data and averages; (9) methods codes; (10) sediment specific surface area; (11) sediment percent carbon and nitrogen; (12) sediment gravimetric moisture and averages; (15) sediment X-ray diffraction (XRD) data; (16) sediment adenosine triphosphate (ATP) and averages; (17) a subfolder with sediment incubation respiration data, scripts, and plots; (18) surface water and sediment FTICR methods; and (19) a subfolder of 9.4 Tesla (9.4T) FTICR-MS data. This folder contains five subfolders, one containing the sediment .xml data files, one containing the water .xml files, one containing the sediment CoreMS output files, one containing the water CoreMS output files, and the other containing instructions and scripts for processing the files in CoreMS (https://github.com/EMSL-Computing/CoreMS).The sensor data subfolder contains (1) a subfolder with miniDOT dissolved oxygen and temperature data and plots; (2) miniDOT dissolved oxygen and temperature summary data; and (3) miniDOT installation methods. All files are .csv, .pdf, .R, .xml, .d, .html, .Rmd, .py, .cal, .json, .jpg, .jpeg, .png, .mov, or .mp4. CORRECTION: Carbon and nitrogen content are reported as percentages. The current column headers "01395_C_percent_per_mg" and "01397_N_percent_per_mg" are incorrect. These should read "01395_C_percent" and "01397_N_percent" and will be corrected in the next version of this data package. We thank the United States Forest Service, Washington Department of Fish and Wildlife, Washington Department of Natural Resources, Cowiche Canyon Conservatory, Washington State Parks and Recreation Commission (Scientific Research Permit #210901), and the Confederated Tribes and Bands of the Yakama Nation for access to field locations where the samples labeled “SSS” were collected. We also thank the Yakama Nation Tribal Council and Yakama Nation Fisheries for working with us to facilitate sample collection and optimization of data usage according to their values and worldview. WHONDRS consortium members were asked to provide any acknowledgments for the collection of samples labeled “CM” and the following is a list of acknowledgments that were submitted with their corresponding Site IDs: (MART) Research activities were conducted in part on the Wind River Experimental Forest within the Gifford Pinchot National Forest; (MP- 100379) Philadelphia is part of Lenapehoking, the ancestral homelands of the Lenape peoples; (MP-102398) Land surveyed is the ancestral homelands of the Nookhose'iinenno (Arapaho), Tsis tsis'tas (Cheyenne), and Nuuchu (Ute); (MP-100749 and MP- 100747) Georgia Coastal Ecosystem LTER, OCE-1832178; (SP-70 and SP-72) Eastern Shoshone, Shoshone-Bannock; (MP- 102944) Funded by Oregon Watershed Enhancement Board. On the traditional lands of the Confederated Tribes of the Siletz, Confederated Tribes of the Grand Rhonde, and the Clatsop-Nehalem Confederated Tribe; (MP- 100607) Holiday Creek is located on the traditional territory of the Monacan Indian Nation; (SP-45) Lafayette Blue Springs State Park; (MP-102420) NSF DEB-2016749; (MP-100019) New Hampshire Agriculture Experiment Station; (SP-35) Rayonier (land owner; https://www.rayonier.com/); (MP- 101276) US Department of Energy, Office of Science, Biological and Environmental Research, Subsurface Biogeochemical Research, Watershed Dynamics and Evolution SFA at ORNL; (MP- 103224) Watershed Dynamics and Evolution SFA at ORNL; (MP- 101584) Traditional lands of the Oceti Sakowin (Dakota, Lakota, Nakoda) and Anishinaabe Peoples.
High-Resolution Spatio-Temporal Estimation of Net Ecosystem Exchange in Ice-Wedge Polygon Tundra Using In Situ Sensors and Remote Sensing Data
Land-atmosphere carbon exchange is known to be extremely heterogeneous in arctic ice-wedge polygonal tundra regions. In this study, a Kalman filter-based method was developed to estimate the spatio-temporal dynamics of daytime average net ecosystem exchange (NEEday) at 0.5-m resolution over a 550 m by 700 m study site. We integrated multi-scale, multi-type datasets, including normalized difference vegetation indices (NDVIs) obtained from a novel automated mobile sensor system (or tram system) and a greenness index map obtained from airborne imagery. We took advantage of the significant correlations between NDVI and NEEday identified based on flux chamber measurements. The weighted average of the estimated NEEday within the flux-tower footprint agreed with the flux tower data in term of its seasonal dynamics. We then evaluated the spatial variability of the growing season average NEEday, as a function of polygon geomorphic classes; i.e., the combination of polygon types—which are known to present different degradation stages associated with permafrost thaw—and microtopographic features (i.e., troughs, centers and rims). Our study suggests the importance of considering microtopographic features and their spatial coverage in computing spatially aggregated carbon exchange.
Winds and wind shear in-situ sensors
The problem of development of instrumentation for providing wind speed and direction information directly or indirectly to a pilot in the cockpit is considered. The pilots need for horizontal wind information at various stages of flight (i.e., at liftoff, in approach and departure corridors, and even in flight outside the terminal area) are emphasized.
Demonstrating Advanced Sensors for In-Situ Monitoring Towards Qualification of Nuclear Relevant Components
The U.S. Department of Energy’s Office of Nuclear Energy Advanced Materials and Manufacturing Technologies (AMMT) program is pursuing qualification of laser powder bed fusion (LPBF) components for nuclear applications. A major focus of this effort is the use of in situ process monitoring and machine learning–based tools to establish real-time quality assurance. The primary objective of this report is to identify and evaluate the most relevant in situ sensor systems for LPBF, and to document the deployment of these systems across platforms critical to the AMMT program. This work demonstrates how in situ monitoring can detect process anomalies, track geometry-dependent flaws, and identify limiting combinations of processing parameters—particularly those related to energy density and complex geometries (e.g., overhanging structures). To support this goal, a diverse suite of sensor modalities was evaluated across LPBF platforms, including visible and near-infrared (NIR) imaging, fringe projection profilometry, long-wavelength infrared (LWIR) thermography, and high-speed photodiode/pyrometry systems. These sensor streams were integrated with Peregrine, a machine-agnostic software platform that, among other capabilities, can generate real-time process anomaly classification. This report documents sensor deployments on multiple AMMT flagship platforms, including the Concept Laser M2 and Renishaw AM400/AM250 systems. Calibration builds with complex, flaw-prone geometries such as unsupported overhangs, stepped features, and thin walls, were used to evaluate how well Peregrine and its associated sensors could detect process anomalies and other instabilities under varied energy densities. It will be shown how Peregrine reliably identifies common process anomalies such as recoater streaking, superelevation, etc., and can be used in post-build analysis for anomaly spatial distributions throughout the build height to better understand the impact of geometry and processing parameter choice on the build. This work demonstrates measurable progress toward the vision that components can be born-qualified by establishing a real-time monitoring framework, identifying limiting process conditions, and laying the foundation for sensor fusion–enabled prediction pipelines that are scalable across platforms and applicable to nuclear-relevant components.
Exploration Architecture with Quantum Inertial Gravimetry and In-Situ ChipSat Sensors
The Dual Exploration Architecture is a mission concept that combines remote sensing and in-situ observations into a single mission to answer planetary science questions that can only be answered with both types of data. Adoption of dual exploration architectures may short circuit the long, slow cycle of missions to inaccessible bodies by eliminating the need for separate precursor and follow-up missions. Additionally, the dual architecture possesses inherent flexibility that enables the design of adaptive, event-driven missions that are very different from traditional, largely pre-planned missions. Five key observations about the state and trends of planetary science exploration lead us to the dual architecture: increasing complexity of observations; scarcity of future mission opportunities; desire to capture transitory events; continued miniaturization of spacecraft components; and the Mars exploration cycle. Our goal in this study is to explore missions that can only happen using the dual architecture concept and find technology development needs that must be filled for those missions to compete. A survey of historical and current missions finds that opportunities for exploration are becoming less frequent, causing the flexibility and dual-nature elements of each mission to become more common. The dual exploration architecture takes these trends to their far conclusion, attempting to eliminate precursor and follow-up missions while still returning more scientific payoff. A study of the future of planetary science goals through the decadal survey reveals broad applicability of dual missions to solve mysteries that cannot be answered with a traditional mission architecture. These missions fall into three broad classes: choosing a local target from a global survey; dynamic/reactive science; and global in-situ networks. Two example missions of each class are notionally described. A deeper look at these dual architecture classes reveals four technology development needs that must be addressed for wide adoption of dual missions: passive landers; guided atmospheric probes; robust sensing packages; and small, precise orbital instruments. This study pursues a specific focus on two examples of such enabling technologies: the ChipSat and cold atom gravimetry. The ChipSat is a fully functional spacecraft-on-a-chip system that has broad versatility in the dual architecture mission space. Initial studies show that ChipSats could survive as passive impactor landers on bodies up to the size of Europa. Furthermore, COTS (Commercial Off-The-Shelf) components could provide an in-situ sensor suite that readily answers a number of pressing planetary science questions. Cold atom gravimetry uses inertial sensors based on light-pulse atom interferometry in a small form factor to map the gravity field of a body to precision equaling what would normally require two full spacecraft to achieve. The cold atom gravimeter provides an example of how advanced remote sensing capability can enable dual missions by providing greater returns in a significantly smaller package. Using the above two technologies, we study an example dual-architecture mission to both characterize and sample the subsurface oceans at Europa. The greatest scientific return in terms of detecting extraterrestrial life is in those regions where Europa’s ice crust is thin. The identification of regions with thin ice should therefore precede the selection of surface targets and dispatch of probes to those targets. This two-step process, if accomplished by separate flagship-scale missions, might take decades. As a result, a combined mission to both identify thin areas of Europa’s ice and follow up with surface observations at those regions is a good candidate for the dual-exploration architecture. This example mission consists of an orbiter spacecraft carrying a cold atom gravimeter capable of sensing or inferring the ice thickness on regional to local scales, along with a number of ChipSat probes capable of landing on the moon. The small size and weight of the ChipSats allows large numbers of them to be carried, ensuring that enough can be dropped to ensure survival of a minimum number of probes and potentially allowing for the in-situ sampling of multiple locations on the moon. The example missions and Europa case study show that amazing scientific return can obtained from dual-exploration architecture missions with a single launch by breaking the long timescales of planetary exploration and providing the flexibility to capturing transitory events and collect data across the local, regional, and global scales.
Development of a Portable In Situ Phosphorous Sensor
While phosphorus is a critical nutrient for all forms of life, runoff leads to phosphorus accumulation in surface water where it can cause a variety of health, environmental, and economic problems. The Department of Energy is interested in conducting long-term field experiments to monitor the impact of phosphorus in terrestrial and aquatic environments, and to better understand a cost vs. benefit analysis of reducing phosphorus pollution. Performing such long-term experiments requires affordable sensors capable of monitoring low-level phosphorus concentrations under challenging environmental conditions. However, such sensors are currently not available. The goal of this proposed project is to develop and demonstrate a low-cost portable phosphorus sensor suitable for in situ measurements. We will determine the technical requirements for a Raman-based sensor system, design and build a signal amplifier, integrate it with a Raman-based sensor, and demonstrate a proof-of-concept level sensor system. The expected accomplishments for Phase I include the identification of the technical requirements of a combined Raman laser/spectrometer and cavity enhancement system, building a proof-of-concept level sensor system capable of detecting orthophosphate compounds at the desired level of 0.25 mg P/L and organic P compounds, and verification of the sensor performance under laboratory and field conditions. In addition, we will identify initial hardening requirements that will need to be implemented during Phase II. While we plan to develop an integrated sensor system for monitoring phosphorus, the cavity-based enhancement system can also be used in combination with other (non-phosphorus) Raman sensors that we plan to develop or that are already commercially available. A recent market report highlights the increasing demand for such environmental monitoring applications, with the market for chemical detection anticipated to grow at a compound annual growth rate of 6.5% (2020-2025). Wide-spread monitoring of phosphorus could reduce the damage from eutrophication in freshwater, which is estimated to be $2.2 billion annually, thereby increasing biodiversity, reducing costs required for drinking water treatment, and decreasing economic losses related to recreation and angling and lake property values.
Introducing the Video In Situ Snowfall Sensor (VISSS)
The open-source Video In Situ Snowfall Sensor (VISSS) is introduced as a novel instrument for the characterization of particle shape and size in snowfall. The VISSS consists of two cameras with LED backlights and telecentric lenses that allow accurate sizing and combine a large observation volume with relatively high pixel resolution and a design that limits wind disturbance. VISSS data products include various particle properties such as maximum extent, cross-sectional area, perimeter, complexity, and sedimentation velocity. Initial analysis shows that the VISSS provides robust statistics based on up to 10 000 unique particle observations per minute. Comparison of the VISSS with the collocated PIP (Precipitation Imaging Package) and Parsivel instruments at Hyytiälä, Finland, shows excellent agreement with the Parsivel but reveals some differences for the PIP that are likely related to PIP data processing and limitations of the PIP with respect to observing smaller particles. The open-source nature of the VISSS hardware plans, data acquisition software, and data processing libraries invites the community to contribute to the development of the instrument, which has many potential applications in atmospheric science and beyond.
Case Study Analyses of the SUCCESS DC-8 Scanning Lidar Database
Under project SUCCESS (Subsonic Aircraft Contrail and Cloud Effects Special Study) funded by the Atmospheric Effects of Aviation Program, SRI International (SRI) developed an angular scanning backscatter lidar for operation on the NASA DC-8 research aircraft and deployed the scanning lidar during the SUCCESS field campaign. The primary purpose of the lidar was to generate real-time video displays of clouds and contrails above, ahead of, and below the DC-8 as a means to help position the aircraft for optimum cloud and contrail sampling by onboard in situ sensors, and to help extend the geometrical domain of the in situ sampling records. A large, relatively complex lidar database was collected and several data examples were processed to illustrate the value of the lidar data for interpreting the other data records collected during SUCCESS. These data examples were used to develop a journal publication for the special SUCCESS Geophysical Research Letters issue. The data examples justified data analyses of a larger part of the DC-8 lidar database and is the objective of the current study. Efficient processing of the SUCCESS DC-8 scanning lidar database required substantial effort to enhance hardware and software components of the data system that was used for the initial analyses. MATLAB instructions are used to generate altitude and distance color-coded lidar displays corrected for effects introduced by aircraft pitch and forward movement during an angular scan time interval. Onboard in situ sensor atmospheric measurements are propagated to distances ahead of the DC-8 using recorded aircraft velocity so that they can be plotted on the lidar displays for comparison with lidar remotely observed aerosol distributions. Resulting lidar and in situ sensor polar scan displays over extended sampling intervals are integrated into a time series movie format for 36 case studies. Contrails and clouds were detected to ranges of 15 km by the forward-viewing angular scanning lidar and were progressively mapped as the aircraft approached and penetrated them. Near aircraft lidar observations were much better correlated with in situ sensor observations than lidar observations at greater distances ahead of the aircraft. The major cause of this difference was thought to be the about 2 deg. offset of the lidar viewing direction from the flight direction. Contrail spatial distributions were not of the quality obtainable from ground-based lidar observations. This results because contrails tend to become horizontally stratified, vertical distance between angular lidar observations increases with increased distance from the aircraft, and erratic aircraft motions during an angular scan. The most useful lidar observations were made with lidar viewing directions of vertically upward or vertically downward. These provided real-time information on aircraft altitudes to achieve optimum in situ cloud and contrail sampling. At sampling altitudes, the forward viewing angular scanning observations were useful for fine-tuning the aircraft altitude for cloud and contrail penetration. Best information on cloud and contrail properties were obtained from vertically directed lidar observations as the aircraft performed a series of upward and downward penetrations of contrails. This operational mode was especially well suited for lidar and radiometric evaluation of cloud and contrail optical and radiative properties. The vertical viewing lidar detected ice crystals thought to be precipitating from an aircraft contrail and their scavenging by a cirrus cloud layer. The lidar display indicates that the crystals are effective for increasing cirrus cloud density. Vertical angular scanning observations can evaluate the sharp decrease in lidar backscatter for small off-vertical viewing directions that result from horizontally aligned ice crystals and perhaps can provide additional information on crystal shapes. The about 2 deg. offset of the lidar viewing direction from the flight direction is thought to have greatly degraded the forward-viewing angular scanning observations and this mode of operation was not fully evaluated. However, the reasoning for this capability remains valid and the angular scan presentations collected during this program justifies modification of the lidar pod for true forward direction lidar viewing during future cloud and contrail studies.
Measurements from mobile surface vehicles during the Lower Atmospheric Profiling Studies at Elevation – a Remotely-piloted Aircraft Team Experiment (LAPSE-RATE)
Abstract. Between 14 and 20 July 2018, small unmanned aircraft systems (UASs) were deployed to the San Luis Valley of Colorado (USA) alongside surface-based remote sensors, in situ sensors, and radiosonde systems as part of the Lower Atmospheric Profiling Studies at Elevation – a Remotely-piloted Aircraft Team Experiment (LAPSE-RATE). The measurements collected as part of LAPSE-RATE targeted quantities related to enhancing our understanding of boundary layer structure, cloud and aerosol properties and surface–atmosphere exchange and provide detailed information to support model evaluation and improvement work. Additionally, intensive intercomparison between the different unmanned aircraft platforms was completed. The current paper describes the observations obtained using three different types of surface-based mobile observing vehicles. These included the University of Colorado Mobile UAS Research Collaboratory (MURC), the National Oceanic and Atmospheric Administration National Severe Storms Laboratory Mobile Mesonet, and two University of Nebraska Combined Mesonet and Tracker (CoMeT) vehicles. Over the 1-week campaign, a total of 143 h of data were collected using this combination of vehicles. The data from these coordinated activities provide detailed perspectives on the spatial variability of atmospheric state parameters (air temperature, humidity, pressure, and wind) throughout the northern half of the San Luis Valley. These datasets have been checked for quality and published to the Zenodo data archive under a specific “community” setup for LAPSE-RATE (https://zenodo.org/communities/lapse-rate/, last access: 21 January 2021) and are accessible at no cost by all registered users. The primary dataset DOIs are https://doi.org/10.5281/zenodo.3814765 (CU MURC measurements; de Boer et al., 2020d), https://doi.org/10.5281/zenodo.3738175 (NSSL MM measurements; Waugh, 2020), and https://doi.org/10.5281/zenodo.3838724 (UNL CoMeT measurements; Houston and Erwin, 2020).
Field Testing of a Two-Micron DIAL System for Profiling Atmospheric Carbon Dioxide
A 2-m DIAL system has been developed at NASA Langley Research Center through the NASA Instrument Incubator Program. The system utilizes a tunable 2-m pulsed laser and an IR phototransistor for the transmitter and the receiver, respectively. The system targets the CO2 absorption line R22 in the 2.05-m band. Field experiments were conducted at West Branch, Iowa, for evaluating the system for CO2 measurement by comparison with in-situ sensors. The CO2 in-situ sensors were located on the NOAA's WBI tower at 31, 99 and 379 m altitudes, besides the NOAA s aircraft was sampling at higher altitudes. Preliminary results demonstrated the capabilities of the DIAL system in profiling atmospheric CO2 using the 2-m wavelength. Results of these experiments will be presented and discussed.
CO-115GHz and 345GHz concentration-dependent absorption measurement for in-situ gas sensor development
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Development of in situ thickness sensor for vapor diffused Nb3Sn films
Fermilab is one of the leaders in development of vapor diffused Nb3Sn films inside niobium cavities. This material has a higher critical temperature (Tc) than niobium, enabling cavity operation at 4.2 K. This higher operational temperature significantly reduces the infrastructure required for cooling compared to 2 K systems, making superconducting radio-frequency (SRF) technology more accessible. Current deposition methods have relied on iterative testing to determine nominal film thickness, a process that can be time-consuming and imprecise. To address this, we are developing a sensor to measure the thickness of Nb3Sn thin film in situ during vapor diffusion. Our design involves the resistance measurement of a thin film of niobium. During coating, the change in resistance reflects the conversion of the film to Nb3Sn, which allows simple integration with the current furnace infrastructure. This sensor would allow real time measurement of the thickness, allowing for increased precision in future depositions.
Development of in situ thickness sensor for vapor diffused Nb3Sn films
Fermilab is one of the leaders in development of vapor diffused Nb3Sn films inside niobium cavities. This material has a higher critical temperature (Tc) than niobium, enabling cavity operation at 4.2 K. This higher operational temperature significantly reduces the infrastructure required for cooling compared to 2 K systems, making superconducting radio-frequency (SRF) technology more accessible. Current deposition methods have relied on iterative testing to determine nominal film thickness, a process that can be time-consuming and imprecise. To address this, we are developing a sensor to measure the thickness of Nb3Sn thin film in situ during vapor diffusion. Our design involves a four-point resistance measurement of a thin film of niobium, inside the coating region. During coating, the change in resistance reflects the conversion of the film from Nb to Nb3Sn, which allows simple integration with the current furnace infrastructure. This sensor would allow real time measurement of the Nb3Sn film thickness, allowing for increased precision in future depositions for cavity applications.
A comparative study of measurements from radiosondes, rocketsondes, and satellites
Direct comparisons of operational products derived from measurements of radiance by satellites to measurements from conventional in situ sensors are important for the evaluation of satellite systems. However, errors in the in situ measurements themselves complicate such comparisons. Atmospheric temporal and spatial variability are also influential. These issues are investigated by means of a special field program composed of flights of dual radiosondes and multiple radiosondes launched near the time of NOAA-6 overpasses. Satellite derived mean layer temperatures, geopotential heights, and winds are compared with the same quantities determined from the in situ sensors. Of particular interest is the impact of in situ errors on these comparisons. It is shown that the radiosonde provides a precise pressure height relationship and therefore precise data for synoptic type use. Radar tracking of the radiosondes reveals, however, an imprecise pressure measurement which causes large differences between the actual altitude of the radiosonde and the altitude at which it is calculated to be. Radiosondes should be radar tracked and pressures calculated if the data are to be used for purposes other than synoptic use. Evaluation of rocketsonde data reveals a temperature precision of 1 to 2 K below about 55 km. Above 55 km, the precision decreases rapidly; rms differences of up to 11 K are obtained.
In situ embedment of type K sheathed thermocouples with directed energy deposition
Advanced nuclear reactor systems require new technologies for heat transfer and system monitoring. Additive manufacturing (AM) offers the design flexibility to allow in-situ sensor embedment through smart manufacturing for real-time monitoring, and performance of these systems. Here, this study focuses on experiments investigating the feasibility of in-situ sensor embedment using directed energy deposition (DED). Type K thermocouples are embedded into 316L stainless steel (SS) samples using two different configurations (e.g., exposed and embedded tips) and two designs (e.g., flush to substrate) within an AM base. Embedded sensor samples are analyzed via in-situ measurements and high-temperature performance validation tests at 350ºC and 900ºC. Temperature performance results at both temperature tests show good agreement with manufacturer specifications proving that these sensors could still capture accurate temperature readings after in-situ embedment during DED processing. An additional optimization experiment was conducted on the exposed tip configuration using a surrogate thermocouple to improve tolerances and the embedment process. Results improved tolerances, lower porosity, smaller gaps between the sensor and base, and better junction contact for the sensor. Although further optimization of this embedment strategy is necessary to improve the structural stability and tolerances within the component, this research strategy provides a proof-of-feasibility for DED embedment with commercial sheathed thermocouples. This research provides early impact on embedment of sensor for multiple materials and complex geometric components..
A Co-Registered In-Situ and Ex-Situ Dataset of Electrical, Acoustic, and CT Characteristics from Wire Arc Additive Manufacturing Process
Recent progress in sensing techniques and data analytics tools have significantly accelerated the development of Wire Arc Additive Manufacturing (WAAM) systems. This data centric approach emphasizes leveraging available data throughout the production process to optimize performance. Integration of extensive data analysis provides the opportunity to improve precision, reduce waste, and enhance the quality of produced parts. This method relies on AI/ML models and optimization techniques, which are developed using the data collected from various sources, including in-situ sensors, ex-situ imaging, and manufacturing process parameters. The quality and diversity of this data, along with the alignment between different data streams (achieved through spatiotemporal registration) are critical for the successful development of AI/ML and optimization models. In this work, we present a spatiotemporally registered dataset generated during the WAAM process of deposition of a rectangular block. The dataset includes the comprehensive description of deposition process, process parameters, in-situ collected welding characteristics, acoustic data, and X-Ray Computed Tomography analysis data for the build. Dataset A Co-Registered In-Situ and Ex-Situ Dataset of Electrical, Acoustic, and CT Characteristics from Wire Arc Additive Manufacturing Process has arisen under UT-Battelle, LLC’s Prime Contract No. DE-AC05-00OR22725 with the U.S. Department of Energy (DOE) to manage and operate the Oak Ridge National Laboratory. UT-Battelle, LLC will not assert any rights under United States law or under the Prime Contract it has in the dataset against any user of the dataset, including any copyrights or patent rights. UT-Battelle, LLC requests that attribution to the dataset is provided as academically appropriate.
Combining In-situ Diagnostics and Data Analytics for Discovery of Process-Structure-Property Relationships in AM parts – A Step Toward Digital Twins
In-situ additive manufacturing (AM) diagnostic tools (e.g., optical/infrared imaging, acoustic, etc.) already exist to correlate process anomalies to printed part defects. This current work aimed to augment existing capabilities by: 1) Incorporating in-situ imaging w/ machine learning (ML) image processing software (ORNL- developed "Peregrine") for AM process anomaly detection 2) Synchronizing multiple in-situ sensors for simultaneous analysis of AM build events 3) Correlating in-situ AM process data, generated part defects and part mechanical properties The key R&D question investigated was to determine if these new combined hardware/software tools could be used to successfully quantify defect distributions for parts build via SNL laser powder bed fusion (LPBF) machines, aiming to better understand data-driven process-structure-property- performance relationships. High resolution optical cameras and acoustic microphones were successfully integrated in two LPBF machines and linked to the Peregrine ML software. The software was successfully calibrated on both machines and used to image hundreds of layers of multiple builds to train the ML software in identifying printed part vs powder. The software's validation accuracy to identify this aspect increased from 56% to 98.8% over three builds. Lighting conditions inside the chamber were found to significantly impact ML algorithm predictions from in-situ sensors, so these were tailored to each machine's internal framework. Finally, 3D part reconstructions were successfully generated for a build from the compressed stack of layer-wise images. Resolution differences nearest and furthest from the optical camera were discussed. Future work aims to improve optical resolution, increase process anomalies identified, and integrate more sensor modalities.