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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 361 records · Page 20
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Continuous Water Quality Sensing for FGD Wastewater

The coal fired plant power industry requires new solutions for on-line monitoring of flue gas desulfurization (FGD) wastewaters for regulated trace metals to reduce recurring operating and off-site laboratory analysis costs and provide a high level of confidence of compliance with state and federal discharge guidelines. The University of Alabama at Birmingham (UAB) developed an integrated water sensor package for continuous water quality monitoring of flue gas desulfurization (FGD) wastewaters for concentration measurements of Selenium (Se). UAB utilized a diverse team of University Professors/Staff Members/Student(s) (Engineering and Innovative Technology Development Group), a University Affiliated Research Institution from the local area (Southern Research), and a cost sharing Industry Partner (Metrohm). The team developed and validated a proprietary wet chemistry batch process for water sample preparation; and implemented this process as a fully automated on-line monitor prototype system. This prototype system’s performance was evaluated in both the laboratory and during in-field deployment to a coal fired power plant. In both environments it was found that the prototype system was unable to recreate the batch process’s success at preparing FGD water samples for total Se measurements with a commercial-off-the-shelf (COTS) cyclic anodic stripping voltammetry (CSV) system. Through this experience, UAB has provided insight into a number of specific areas where improvements can be made with respect to the COTS systems used in this project to yield a more complete and competitive industry solution for on-line monitoring of total Se in industrial wastewater.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2026

A Comparative Analysis of Infrastructure-Based Perception Sensors for Intelligent Transportation Systems

The rise of privatized and public investment in smart city infrastructure and intelligent transportation systems has generated a heightened demand for perception sensors that effectively track and detect objects while being reliable in diverse weather and lighting conditions. This growing demand for perception sensors has accelerated their development and enhanced their capabilities. With these new capabilities, it is challenging to determine the most suitable sensing unit to use in each situation. Therefore, it is essential to have a comprehensive understanding of the benefits and limitations of each sensing unit to effectively leverage their capabilities. The purpose of this paper is to provide a detailed evaluation of various perception sensors. Additionally, this paper will demonstrate the benefits of combining multiple perception sensors, which complement each other by addressing data gaps inherent to single-sensor systems, to facilitate the creation of a digital twin that models the real world. The Infrastructure, Perception, and Control (IPC) team will conduct data analysis using data collected through field testing at traffic intersections in Colorado Springs, Colorado, to make comparisons between sensors. This research aims to provide clear and concise information about modern perception systems, which will support the development of intelligent transportation systems.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2023

EmSense: A High-Resolution Emulated Sensor for Experiments with the Smart Grid and Distributed Ledger Technology

This work involves the development of a device - EmSense (“Emulated Sensor”) - that emulates a high-resolution sensor for a power grid. The device collects raw current and voltage sensor data which derive from ORNL's signature library. This library is a dataset that ORNL curates from many different sources that include power systems from various utilities. The EmSense packages the data from the library in the form of IEC 61850 Sampled Value (SV) packets and then broadcasts these SV packets on the network. In another mode, EmSense can generate artificial sinusoidal data that appears as waveforms for voltage and current signals. EmSense has an internal algorithm for determining the period of a signal based on the data so that the period can be specified as a variable in the IEC 61850 packets. The purpose of EmSense is to allow for experimentation with the Dark Net Infrastructure where a variety of power line sensors must be represented along with their typical communication traffic. The EmSense device was developed in coordination with the software for receiving and processing the packets in the Distributed Ledger Technology (DLT) framework of the DarkNet Project. This receiving software must have a methodology for dealing with information of high velocity, variety, and volume. Experimenting with EmSense facilitates the development of such software. The results showed that the DLT framework and the trust-anchoring approach managed to process a large flow of traffic even with up to six instances of EmSense device broadcasting data. This was achieved without overfilling packet queues in the memory of the actual hardware of the DLT devices or causing the Central Processing Unit (CPU) of the hardware to be overwhelmed. The DLTs were also able to store the data in a compact and useful form for later analysis and archival purposes.

Werth, Aaron↗
DOE OSTI2026

Robust Heat-Flux Sensors for Coal-Fired Boiler Extreme Environments

In this project, robust heat-flux measurement systems were developed. The heat-flux sensors utilize thermoelectric effects to directly transduce the heat-flux inputs to analog electrical voltage signals. They were constructed from dedicated materials that can withstand temperatures of at least 1000°C and maintain adequate performance at these conditions for prolonged periods of time. The proposed approaches took into account numerous considerations, including system cost, sensor head resilience, sensor footprint, data accuracy, response time, and maintenance requirements. Through modern thermoelectric materials design, methodical materials selection and rigorous testing in materials characterization labs and medium-scale fire research facilities, we have demonstrated functioning laboratory prototypes, upon which one could base industrial heat-flux sensing platforms capable of operating in the challenging high-temperature, corrosive environments of the boilers of coal-fired power plants. A distributed sensor array for heat-flux measurements throughout the furnace water-wall, the superheater area and the economizer coils can provide critical data for the power plant control systems to increase efficiency, improve safety and reduce down times. For example, the combined heat-flux sensor/control systems can contribute to the optimization of burner and boiler operations under flexible loads, the optimization of heat-exchange conditions and overall reduction of heat rate and emissions, the prediction of imminent overheating conditions, and the optimization of the soot-blowing protocols.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2025

Model Development and Analysis of a High-Fidelity Neutron Transport Sensor: The Quadrupole Detector Concept for Measurement of the Neutron Flux Gradient

Accurate reconstruction of the neutron flux distribution within a reactor core is essential for safe and efficient reactor operation. Traditional power shape synthesis in Light Water Reactors relies on hundreds of in-core detectors. However, this approach becomes impractical for Advanced Reactors and Microreactors due to limited space and harsh environments. To address this challenge, we propose a data-driven methodology that combines high-fidelity modeling with real-time ex-core sensor measurements, enabling the reconstruction of core power distribution while minimizing the reliance on intrusive in-core instrumentation. This project began in FY24 and achieved two initial milestones: (1) the definition of a three-year development plan for a Digital Twin framework and (2) the development of high-fidelity neutronics models of the Purdue University Reactor One (PUR-1) using both MCNP6 and OpenMC. The PUR-1 reactor, a zero-power facility, was selected due to its suitability for neutronics-focused modeling and the availability of experimental data for validation. Both models were benchmarked using neutron flux measurements obtained from irradiated gold foils, which were strategically placed within the core during a dedicated campaign in July 2024. This report marks the continuation and completion of those foundational tasks. The OpenMC model has been refined (improved geometric accuracy, expanded cross-section libraries, and refined sampling) and validated using additional experimental data. An updated sensor design—based on quadrupole configuration—was designed to measure both ex-core flux and its spatial gradient. These measurements will serve as inputs to a neural network-based reconstruction algorithm. Finally, the methodology was demonstrated on a two-dimensional test case representative of the heterogeneous material composition of the PUR-1 reactor core. A neural network implementation of the Kirchhoff-Helmholtz integral equation was employed to solve the boundary value problem using peripheral sensor measurements. The preliminary results confirm the strong potential of the proposed approach for accurate and minimally invasive neutron flux reconstruction.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Estimation of cutting tool wear using an elastomeric tactile sensor

Machining performance of cutting tools and part quality are affected by the geometric condition of the cutting edge, which is influenced by thermomechanical loads experienced during the process. Tool condition monitoring (TCM) systems provide insight for timely replacement of cutting tools. However, existing TCM systems are expensive and require specialized equipment or sensors, hindering widespread adoption. A novel TCM system is developed herein using an elastomeric tactile sensor. Sensor images of the cutting edge are used to quantify wear using two distinct algorithms. In the first algorithm, the unworn and worn edges are identified based on Canny edge detect. In the second, the unworn edge is identified using edge detection while the region of wear is identified using a relative intensity method. In both cases, the maximum wear width is calculated based on an experimentally determined pixel to-physical distance scale. The TCM system is first used to estimate flank wear on a solid carbide helical end mill before evaluating its robustness by employing it to estimate insert wear of an indexable helical end mill. Measurements are also performed manually using an optical microscope and a high-resolution focus variation microscope for verification. The novel technique estimates flank wear in the solid carbide tool with a high accuracy of 98%. Larger discrepancies are observed for the inserts, however, with overlapping uncertainties. In conclusion, the technique shows promise in adaptability, automation, and closed loop control of machine tools.

Machining↗
DOE OSTI2022

Development of Quality Control Methods for Robust and Reliable Sensor Design

The successful adoption of additive manufacturing for the rapid prototyping of printed sensors requires the establishment of quantifiable metrics that can interrogate device performance. One measure of performance is the adhesion strength between the substrate and sensor interface, which is critical since the strength of this interface can dictate the accuracy and reliability of the printed sensor. In this work, a non-contact laser-induced spallation technique was used to quantify the adhesion of silver prints on an aluminum alloy substrate. The laser-based method was compared to a standardized pull-off adhesion test, which provided baseline measurements of adhesion strength. The sintering conditions were shown to play an important role in the film-substrate adhesion strength, as well as the cohesion and ductility of the film itself. The methods and results described in this work supports the establishment of process control steps that are necessary for verifying the reliability of printed devices prior to its deployment in critical experiments.

36 MATERIALS SCIENCE↗
DOE OSTI2020

CORC $^{\circledR}$ cable terminations with integrated Hall arrays for quench detection

ReBCO superconducting cables have the potential to enable compact thermonuclear fusion reactors that operate at magnetic fields exceeding 20 T and allow operation at temperatures far exceeding the boiling point of liquid helium, potentially allowing for demountable magnets. Normal zone detection remains a challenge, and while novel quench detection techniques are an active area of research, few are non-invasive, provide real-time quench detection, and have been demonstrated with current ramp rates relevant for fusion reactors. To address this problem, a CORC$^{\circledR}$ cable termination is developed with integrated Hall sensors to monitor current redistribution as a proxy for quench detection. The methodology exploits the current sharing and layered topology in CORC$^{\circledR}$ cables, and allows quench detection using a localized sensor instead of co-wound voltage wires or optical fibers. Furthermore, experiments are presented where current redistribution is measured from induced quenches, and in a 0.2 meter CORC$^{\circledR}$ sample it is found that the Hall sensors detect normal zone transitions with a similar magnitude and temporal resolution as voltage measurements. To emulate the conditions of dynamic poloidal and central solenoidal fields, experiments are repeated with ramp rates up to 10 kA s -1 that demonstrate the potential to detect normal zone development over a range of experimental parameters.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2022

Incipient Sensor Fault Impacts on Building Performance Through HVAC Controls: A Pilot Study

Sensors are crucial input components for HVAC controls. Studies show faults are common for buidings and HVAC systems. Sensors with faults will compromise the control perfrormance regardless how advanced of the control algorithms. Majority studies assume the sensor fault to be constant the whole year. In reality, the sensor faults might evolve or develop with time, which is essentially the incipient (i.e. evolving) fault. The incipient sensor faults impacts remain a research gap. This study aims to investigate the incipient sensor fault impacts to control sequences of multi-zone VAV boxes and AHU system following the ASHRAE Guideline 36-2018: High-Performance Sequences of Operation.

Li, Yanfei↗
DOE OSTI2021

Optimizing Ventilation Using Low-Cost Sensors to Improve Health, Safety, and Energy Efficiency

Air is the primary carrier of hazards within a space, whether it be hazardous byproducts of laboratory research activities or airborne pathogens. As a result, building ventilation is a primary defense against unseen airborne hazards. Critical laboratory facilities require effective mitigation of exposure to research-related, airborne hazards, providing a proving ground for effective ventilation strategies that optimize safety of occupants and reduce energy use. The heart of smart laboratory building operation is dynamic, analytics-based ventilation, which requires an in-depth intimate knowledge of building environmental conditions achieved through contaminant-detection systems. Unfortunately, currently many contaminant-detection solutions are expensive, elaborate systems that raise barriers for building managers. Through the successful deployment of a novel low-cost, modular sensor technology, we have developed a demand-control ventilation protocol effective in improving safety and reducing energy in critical laboratory environments. In this article, we will highlight best practices and lessons learned through this deployment that can be applied beyond laboratories. This article describes a low-cost sensor to support providing a safe, healthy building environment and reduce energy use through effective and efficient ventilation.

dynamic management of indoor air quality↗
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 ↗
DOE OSTI2021

Electromechanical response of piezoelectric thin films subjected to large strain

The use of piezoelectric thin sensors, when subjected to large static strain levels in ultrasonic applications is reported in this paper. A novel flipped beam bending method is proposed to induce static strain level nearing twice the incipient yield strain in the beam material (~0.39%). First, the effect of static large strain on ultrasonic guided wave propagation in the beam was studied using the velocity measurements obtained from a laser Doppler vibrometer. Next, the ultrasonic response of thin sensors is studied under compressive and tensile static strain (±0.72%) with the sensors symmetrically bonded on the lower and upper surfaces, and at the same axial location. The ultrasonic guided wave response to varying levels of static strain is recorded at different center frequencies (50–400 kHz) of the narrow banded ultrasonic excitation. As a case study, the variation of the ultrasonic guided wave response of polyvinylidene difluoride (PVDF) thin sensors with center frequencies at different static strain levels was analyzed and compared with that of lead zirconate titanate (PZT) thin sensors. PZT sensors show a higher variation of sensing performance with strain when compared to PVDF sensors. Apart from static strain, the possible effects on the change in performance of sensors, such as the change in the capacitance is discussed. The characterization method provides a reusable beam arrangement to study the ultrasonic sensor performance at large static strain levels. Characterization at large strain level allows the development of fail-safe sensors even under large strain and permanent plastic deformation of structure on which they are bonded, allowing accurate ultrasonic structural health monitoring even in the presence of damage progression. Piezopolymer sensor like PVDF are least susceptible to static strain due to large yield strain and low modulus and can serve as fail-safe sensors under large strain.

Rathod, Vivek↗
DOE OSTI2020

Pre-Symptomatic COVID Screening

Temperature checks for fever are extensively used for preliminary COVID screenings but are ineffective during the incubation stage of infection when a person is asymptotic. Researchers at the European Centre for Disease Prevention and Control concluded that approximately 75% of passengers infected with COVID-19 and traveling from affected Chinese cities would not be detected by early screening. Core body temperature is normally kept within a narrow range and has the smallest relative standard deviation of all vital signs. Heat in the body is prioritized around internal organs at the expense of the periphery by controlling blood flow. In fact, blood flow to the skin may vary by a factor of 100 depending on thermal conditions. This adaptation causes rapid temperature fluctuations in different skin regions from changes in cardiac output, metabolism, and likely cytokine diffusion during inflammation that would not be seen in average core body temperature. Current IR and thermal scanners used for temperature checks are not necessarily reflective of core body temperatures and require cautious interpretation as they frequently result in false positive and false negative diagnosis. Hand held thermometers measure average skin temperatures and can get readings that differ from core body temperature by as much as 7°. Rather than focusing on a core body temperature threshold assessment we believe that variability of temperature patterns using a novel wearable transdermal microneedle sensor will be more sensitive to infections in the incubation stage and propose to develop a wearable transdermal temperature sensor using established Sandia microneedle technology for pre-symptomatic COVID screening that can additionally be used to monitor disease progression at later stages.

47 OTHER INSTRUMENTATION↗
DOE OSTI2020

Pre Symptomatic COVID Screening

Temperature checks for fever are extensively used for preliminary COVID screenings but are ineffective during the incubation stage of infection when a person is asymptotic. Researchers at the European Centre for Disease Prevention and Control concluded that approximately 75% of passengers infected with COVID-19 and traveling from affected Chinese cities would not be detected by early screening. Core body temperature is normally kept within a narrow range and has the smallest relative standard deviation of all vital signs. Heat in the body is prioritized around internal organs at the expense of the periphery by controlling blood flow. In fact, blood flow to the skin may vary by a factor of 100 depending on thermal conditions. This adaptation causes rapid temperature fluctuations in different skin regions from changes in cardiac output, metabolism, and likely cytokine diffusion during inflammation that would not be seen in average core body temperature. Current IR and thermal scanners used for temperature checks are not necessarily reflective of core body temperatures and require cautious interpretation as they frequently result in false positive and false negative diagnosis. Hand held thermometers measure average skin temperatures and can get readings that differ from core body temperature by as much as 7°. Rather than focusing on a core body temperature threshold assessment we believe that variability of temperature patterns using a novel wearable transdermal microneedle sensor will be more sensitive to infections in the incubation stage and propose to develop a wearable transdermal temperature sensor using established Sandia microneedle technology for pre symptomatic COVID screening that can additionally be used to monitor disease progression at later stages.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2021

Robust Optical Sensor Technology for Real-Time Monitoring of Solid Oxide Fuel Cells with High Spatial Resolutions

This SOFC core technology development program will develop an integrated fiber optical sensor technology to perform real-time and high-resolution measurements in both planar and tubular fuel cells and fuel cell assembly to monitor operations and structural changes of SOFCs. The new fiber sensing solution can monitor hundreds of points in the 3D fuel cell structures with 5-mm spatial resolutions using one single optical fiber.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2023

Printed Strain Gauges for High Temperature Applications (>300°C)

The real-time understanding of strain and deformation of materials provides prognostic health monitoring of components of current operational reactors and valuable data that shortens the timeline for the development of new nuclear-relevant materials in test reactor experiments. This report discusses the current development and testing of additively manufactured strain gauges. This has potential to improve the sensor design and manufacturing techniques to meet the requirements of the current and advanced nuclear reactors (i.e., in terms of environment conditions, sample geometry, and materials compatibility). The developmental additively manufactured strain gauges are exposed to separate effects testing (i.e., mechanical strain, high temperature) to determine environmental factors that affect the strain gauge. In addition, sensor qualification methodologies are further developed for determining the reliability and robustness at the interface of the AM strain gauge materials.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Scanning Probe Microscope to Map Thermal and Thermoelectric Properties of Combinatorial Materials

The combinatorial methodology offers a high-throughput process for developing radiation-resistant sensor materials for nuclear energy applications through the synthesis and screening of large numbers of compositions and processing conditions in a single process. The combinatorial materials fabrication coupled with an automated screening process enables us to identify the optimal materials composition and processing conditions that yield both desired properties and required irradiation resistance in the most efficient and economic manner. The report focuses on the development of scanning probe technique to map with high resolution the thermal conductivity, Seebeck coefficient and electrical conductivity of combinatory materials with gradient compositions, which has been a key challenge in combinatory materials science. The above three properties play important roles in many sensor materials for nuclear energy applications.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗