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DOE OSTI2026

Enhanced Preparation for Intelligent Cybermanufacturing Systems (EPICS)

Opportunities exist for realizing transformative advances in productivity and reductions in energy footprint through ubiquitous sensing in manufacturing environments. Enhanced Preparation for Intelligent Cybermanufacturing Systems (EPICS) is a 21-month (4 academic semesters, plus one summer) experience for graduate students that focuses on scaling the knowledge, understanding and leadership skills in the cyber manufacturing area. Masters students (8/year, 32 total) complete 2-year projects on industrially-driven project topics, rotating to internships in summer semester to work on scoping and implementation at project partners. Students complete academic training in embedded systems, process modeling, data science, and cloud-based systems design. Their projects are targeted toward sensor retrofit, process monitoring, root cause analysis, and sensor fusion.

Advanced Manufacturing↗

DOE OSTI2020

A Hybrid AI/ML and Computational Mechanics Based Approach for Time-Series State and Fatigue Life Estimation of Nuclear Reactor Components

Environmental fatigue modeling is a complex problem due to multiple failure modes and their intermixing. The failure modes are function of various underlying causes in addition to the corrosive effect of reactor coolant environment. Some of the major causes are time-dependence of material associated with cyclic loading, load sequence effect associated with random/variable amplitude loading, effect of strain amplitude and rates, effect of varying temperature (along both temporal and spatial directions) and the effect of mean strain and stress. The nonlinear intermixing of failure modes associated with above mentioned causing parameters makes the environmental fatigue modeling is a challenging task. Because of this challenge, fatigue is traditionally being modeled based on experimental data. However, test based empirical approach often requires hundreds of fatigue tests to model the above-mentioned intermixing failure causes even for a single material system. The problem is further exaggerated for reactor component made from multi-material systems such as made from both carbon and stainless-steel base metals and their similar and dissimilar metal welds. With the difficulty of conducting hundreds of fatigue tests to capture the above-mentioned intermixing failure causes, fatigue modeling approaches often depends on empirical models based on limited available test data such as available through ASME code and NUREG 6909. However, these limited test-data-based models may not be enough to accurately predict the life of reactor components. Accurate prediction of life of reactor component would become a necessity, particularly when the license of the reactors to be extended for long-term-operation (LTO) that is for well beyond its original design life of 40 years. The requirement of extending the license of reactor under LTO requires hundreds of fatigue tests to be conducted to understand the mechanism associated with the above-mentioned interdependent failure causes. However, conducting large number of fatigue tests is not a feasibility due to the cost involved. To address this issues Argonne National Laboratory (ANL) with the sponsorship of DOE Light Water Reactor Sustainability (LWRS) program trying to develop a hybrid predictive modeling approach. This is based on limited experiment-data, Artificial-intelligence (AI) – Machine-Learning (ML) - Deep-Learning (DL) based techniques and Multiphysics-computational-mechanics based modeling tools. The hybrid approach not-only can improve the accuracy of the existing stress analysis and fatigue modeling approach but also can reduce the over-dependency on test-based approach. Towards this goal following are some of the major contributions based on ANL’s FY-20 environmental fatigue modeling activities: 1) A cyclic plasticity material model database for 82/182 dissimilar metal weld, which can be readily shared with US nuclear industry and regulatory agency on request. 2) A well validated analytical modeling methodology to perform cycle-by-cycle stress prediction under both constant amplitude fatigue loading and variable amplitude fatigue loading (with load-sequence effect). 3) An AI/ML/DL based methodology to predict unmeasurable cyclic strain based on other available sensor signals. This type of approach can be used for estimating strain in real reactor components from other sensor readings. 4) An AI/ML based approach to improve the US capability on environmental fatigue testing. This is by improving ANL’s existing environmental fatigue testing capacity to conduct ASME required strain-controlled tests (by controlling strain amplitudes and its rate), while not measuring the strain (due to the difficulty of placing an extensometer in a narrow autoclave in a PWR-water-test system). 5) A simulation and experiment based probabilistic modeling methodology for time-series fatigue state and life estimation of reactor metal such as dissimilar metal weld.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2014

Novel Modified Optical Fibers for High Temperature In-Situ Miniaturized Gas Sensors in Advanced Fossil Energy Systems

This report covers the technical progress on the program “Novel Modified Optical Fibers for High Temperature In-Situ Miniaturized Gas Sensors in Advanced Fossil Energy Systems”, funded by the National Energy Technology Laboratory of the U.S. Department of Energy, and performed by the Materials Science & Engineering and Electrical & Computer Engineering Departments at Virginia Tech, and summarizes technical progress from July 1st, 2005 –June 30th, 2014. The objective of this program was to develop novel fiber materials for high temperature gas sensors based on evanescent wave absorption in optical fibers. This project focused on two primary areas: the study of a sapphire photonic crystal fiber (SPCF) for operation at high temperature and long wavelengths, and a porous glass based fiber optic sensor for gas detection. The sapphire component of the project focused on the development of a sapphire photonic crystal fiber, modeling of the new structures, fabrication of the optimal structure, development of a long wavelength interrogation system, testing of the optical properties, and gas and temperature testing of the final sensor. The fabrication of the 6 rod SPCF gap bundle (diameter of 70μm) with a hollow core was successfully constructed with lead-in and lead-out 50μm diameter fiber along with transmission and gas detection testing. Testing of the sapphire photonic crystal fiber sensor capabilities with the developed long wavelength optical system showed the ability to detect CO 2 at or below 1000ppm at temperatures up to 1000°C. Work on the porous glass sensor focused on the development of a porous clad solid core optical fiber, a hollow core waveguide, gas detection capabilities at room and high temperature, simultaneous gas species detection, suitable joining technologies for the lead-in and lead-out fibers and the porous sensor, sensor system sensitivity improvement, signal processing improvement, relationship between pore structure and fiber geometry to optical properties, and the development of a sensor packaging prototype for laboratory testing. Analysis and experiments determined that a bonding technique using a CO 2 laser is the most suitable joining technique. Pore morphology alteration showed that transmission improved with increasing annealing temperature (producing smaller pores), while the sensor response time increased and the mechanical strength decreased with increasing annealing temperature. Software was developed for data acquisition and signal processing to collect and interpret spectral gas absorption data. Gas detection on porous glass sensors was completed and the detection limit was evaluated using acetylene and was found to be around 1- 200ppm. A complete materials package for porous glass sensors was manufactured for testing.

36 MATERIALS SCIENCE↗

NASA NTRS1979

The analytical design of spectral measurements for multispectral remote sensor systems

The author has identified the following significant results. In order to choose a design which will be optimal for the largest class of remote sensing problems, a method was developed which attempted to represent the spectral response function from a scene as accurately as possible. The performance of the overall recognition system was studied relative to the accuracy of the spectral representation. The spectral representation was only one of a set of five interrelated parameter categories which also included the spatial representation parameter, the signal to noise ratio, ancillary data, and information classes. The spectral response functions observed from a stratum were modeled as a stochastic process with a Gaussian probability measure. The criterion for spectral representation was defined by the minimum expected mean-square error.

Wiersma, D. J.↗

NASA NTRS1992

Novel approaches to the construction of miniaturized analytical instrumentation

This paper focuses on the design, construction, preliminary testing, and potential applications of three forms of miniaturized analytical instrumentation. The first is an optical fiber instrument for monitoring pH and other cations in aqueous solutions. The instrument couples chemically selective indicators that were immobilized at porous polymeric films with a hardware package that provides the excitation light source, required optical components, and detection and data processing hardware. The second is a new form of a piezoelectric mass sensor. The sensor was fabricated by the deposition of a thin (5.5 micron) film of piezoelectric aluminum nitride (AIN). The completed deposition process yields a thin film resonator (TFR) that is shaped as a 400 micron square and supports a standing bulk acoustic wave in a longitudinal mode at frequencies of approx. 1 GHz. Various deposition and vapor sorption studies indicate that the mass sensitivity of the TFR's rival those of the most sensitive mass sensors currently available, though offering such performance in a markedly smaller device. The third couples a novel form of liquid chromatography with microlithographic miniaturization techniques. The status of the miniaturization effort, the goal of which is to achieve chip-scale separations, is briefly discussed.

Porter, Marc D.↗

NASA NTRS1992

Novel approaches to the construction of miniaturized analytical instrumentation

Porter, Marc D.↗

NASA NTRS1993

A model-based approach for detection of objects in low resolution passive-millimeter wave images

We describe a model-based vision system to assist pilots in landing maneuvers under restricted visibility conditions. The system was designed to analyze image sequences obtained from a Passive Millimeter Wave (PMMW) imaging system mounted on the aircraft to delineate runways/taxiways, buildings, and other objects on or near runways. PMMW sensors have good response in a foggy atmosphere; but, their spatial resolution is very low. However, additional data such as airport model and approximate position and orientation of aircraft are available. We exploit these data to guide our model-based system to locate objects in the low resolution image and generate warning signals to alert the pilots. We also derive analytical expressions for the accuracy of the camera position estimate obtained by detecting the position of known objects in the image.

Tang, Yuan-Liang↗

NASA NTRS1992

Fault detection and diagnosis using neural network approaches

Neural networks can be used to detect and identify abnormalities in real-time process data. Two basic approaches can be used, the first based on training networks using data representing both normal and abnormal modes of process behavior, and the second based on statistical characterization of the normal mode only. Given data representative of process faults, radial basis function networks can effectively identify failures. This approach is often limited by the lack of fault data, but can be facilitated by process simulation. The second approach employs elliptical and radial basis function neural networks and other models to learn the statistical distributions of process observables under normal conditions. Analytical models of failure modes can then be applied in combination with the neural network models to identify faults. Special methods can be applied to compensate for sensor failures, to produce real-time estimation of missing or failed sensors based on the correlations codified in the neural network.

Kramer, Mark A.↗

NASA NTRS2000

TOA Lightning Location Retrieval on Spherical and Oblate Spheroidal Earth Geometries

A simple linear algebraic solution is introduced for retrieving the location and time-of-occurrence of lightning ground strikes on a spherical Earth from a network of four or more time-of-arrival (TOA) sensors. Since the solution accounts for Earth curvature, it represents an extension to earlier planar model results described by Koshak et al. A test of the retrieval method is provided using computer-simulated data sets. The method is easy to comprehend and completely avoids reference to the mathematics of spherical hyperbolas such as discussed by Lewis. A quasi-analytic extension to the spherical Earth solution is provided for an oblate spheroidal Earth geometry, and the importance/relevance of oblate effects are discussed. Future application of these methods in support of the North American National Lightning Detection Network (NALDN) described by Cummins et al. is desirable, but additional theoretical investigations are required to incorporate magnetic bearing information into the present solution process.

Koshak, W. J.↗

NASA NTRS1989

A multi-sensor remote sensing approach for measuring primary production from space

It is proposed to develop a multi-sensor remote sensing method for computing marine primary productivity from space, based on the capability to measure the primary ocean variables which regulate photosynthesis. The three variables and the sensors which measure them are: (1) downwelling photosynthetically available irradiance, measured by the VISSR sensor on the GOES satellite, (2) sea-surface temperature from AVHRR on NOAA series satellites, and (3) chlorophyll-like pigment concentration from the Nimbus-7/CZCS sensor. These and other measured variables would be combined within empirical or analytical models to compute primary productivity. With this proposed capability of mapping primary productivity on a regional scale, we could begin realizing a more precise and accurate global assessment of its magnitude and variability. Applications would include supplementation and expansion on the horizontal scale of ship-acquired biological data, which is more accurate and which supplies the vertical components of the field, monitoring oceanic response to increased atmospheric carbon dioxide levels, correlation with observed sedimentation patterns and processes, and fisheries management.

Gautier, Catherine↗

NASA NTRS2005

Fault Diagnosis in HVAC Chillers

Modern buildings are being equipped with increasingly sophisticated power and control systems with substantial capabilities for monitoring and controlling the amenities. Operational problems associated with heating, ventilation, and air-conditioning (HVAC) systems plague many commercial buildings, often the result of degraded equipment, failed sensors, improper installation, poor maintenance, and improperly implemented controls. Most existing HVAC fault-diagnostic schemes are based on analytical models and knowledge bases. These schemes are adequate for generic systems. However, real-world systems significantly differ from the generic ones and necessitate modifications of the models and/or customization of the standard knowledge bases, which can be labor intensive. Data-driven techniques for fault detection and isolation (FDI) have a close relationship with pattern recognition, wherein one seeks to categorize the input-output data into normal or faulty classes. Owing to the simplicity and adaptability, customization of a data-driven FDI approach does not require in-depth knowledge of the HVAC system. It enables the building system operators to improve energy efficiency and maintain the desired comfort level at a reduced cost. In this article, we consider a data-driven approach for FDI of chillers in HVAC systems. To diagnose the faults of interest in the chiller, we employ multiway dynamic principal component analysis (MPCA), multiway partial least squares (MPLS), and support vector machines (SVMs). The simulation of a chiller under various fault conditions is conducted using a standard chiller simulator from the American Society of Heating, Refrigerating, and Air-conditioning Engineers (ASHRAE). We validated our FDI scheme using experimental data obtained from different types of chiller faults.

Choi, Kihoon↗

DOE OSTI2018

Automation of Data Collection Methods for Online Monitoring of Nuclear Power Plants

Maintenance activities in the United States nuclear power industry are mainly centered on preventive and corrective maintenance. Predictive maintenance, which is a variable time basis maintenance strategy that is dependent on the condition of the equipment, is less utilized but potentially more effective. In the current maintenance practices, the nuclear power plants rely on manual processes to supply information to a human decision making process. The plants have several processes that generate information that is not typically used beyond the intended target for collecting that information. This information is a source of data that is manually collected by labor intensive tasks. The data is therefore expensive to collect, yet limited in use. The industry has realized the opportunity present in reducing the labor intensive tasks by automating them and increasing the uses of the data collected by either developing advanced predictive maintenance methods using data-driven decision making that could span from trending to machine learning and artificial intelligence. This shift in maintenance strategy may result in high cost saving impact. In addition to reducing labor requirements and frequency of maintenance activities, this shift in strategy will reduce the materials portion of the operations and maintenance cost as well. The aim of this specific effort is to focus on the automation of data collection process. It is part of a series of planned efforts to target multiple elements of migrating the current preventive maintenance approach in nuclear power plants to a data-driven approach. These elements include data collection, management, analysis, visualization, in addition to value analysis and change enabling. The other five elements of migration were not considered because they are planned to be explicitly studied in multiple parallel efforts. Challenges including regulations requirements or limitations are planned in a future effort that focuses on change enabling. The risk and benefit/cost of the approach shift is planned in another effort targeted towards value. The storage, communication, computational power, data architecture, and protection are part of the information infrastructure and are planned in dedicated data management effort. The best means to present the data for assisted human decision making is planned in a data visualization effort. The data interpretation and patterns recognition for machine decision making is planned through multiple efforts in data analytics over the following years. This work identified seventeen data sources collection methods in nuclear power plants that could be automated for an integrated data platform that enables comprehensive and informed decision making. For each of the identified seventeen data sources, the base, modern, and state of the art states were described. The current state of data collection used by most utilities was identified as the "base state". The current achievable state was identified as the "modern state", a state that has either been achieved by at least some US utilities or in other industries. The future state that requires research and development to reach was identified as the "state of the art" state. The described states used an out-of-the-box thinking approach. This effort found that there is a hug potential for task automation and data fidelity improvements by evolving the current industry data collection methods. The majority of the processes analyzed were found to be manual and labor intensive and fell in the base state. As a result, the modern state often targeted reducing the manual logging efforts by using electronic and semi-intelligent means or complementing the work with sensors and mobile or fixed technologies that can reduce the demand of labor activities. The state of the art state involved applications advanced methods of data correlation, data mining, and machine learning along with increasing the spatial distribution and fidelity of data, coupling multiple data sources, and enabling the use of sophisticated mobile devices and machine comprehension methods.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2021

Big Data For Operation and Maintenance Cost Reduction

The purpose of this research is to develop a first-of-a-kind framework for integrating Big Data capability into the daily activities of our current fleet of nuclear power plants. Big Data is traditionally defined as data sets with high volume, velocity, and heterogeneity, and the existing Big Data analytics capabilities are now widely popular in fields such as finance, weather, e-commerce, healthcare and sports. In the nuclear industry, while the volume and velocity of data may present computational challenges for existing analytics capabilities, data heterogeneity are seen to present the major challenge. This research project mainly focuses on incorporating the wide range of data heterogeneities in nuclear power plants into an integrated Big Data Analytics capability. The primary end-product of this project is a Big Data framework that is capable of dealing with the large volume and heterogeneity of the data found in nuclear power plants to extract timely and valuable information on equipment performance. The framework can generate system insights that are actionable relations between measurable impacts and the corresponding maintenance action plans and enable optimization of plant operation and maintenance based on the extracted information. The developed framework is capable of handling heterogeneous data including both image data and time-series sensor data. Specifically, this developed framework includes the following components. The first component is an overarching maintenance ontology which includes system insights required by maintenance optimization. The maintenance ontology interacts with other components in the developed framework. The second component handles Piping & Instrumentation Diagram (P&ID) data. It can be used to extract system components and their relations automatically from the P&IDs. This extracted information is stored in the first component, i.e., maintenance ontology, and is also used as input to the third component, i.e., a tool for generating the fault tree for the corresponding system. The generated fault tree in turn is stored in the ontology for assessing risk that is used as a criterion in maintenance policy optimization. The fourth component is a tool for inferring the parameters in the Markov degradation model for a nuclear system. It uses basic information from the ontology. The fifth component is a tool for assessing the degradation level using sensor measurement data, for example, pressure, flowrate. This tool can be used for determining corrective maintenance actions. The results obtained from components four and five are returned to the ontology. The sixth component of the framework is a tool for optimizing the maintenance policy for a nuclear system of interest. It takes certain basic information from the ontology, e.g., costs of maintenance actions and system failures, as input, and returns the optimal maintenance policy to the ontology. This tool can be used for determining predictive maintenance actions. A set of experiments have also been conducted to verify the algorithms developed in this project for nuclear system degradation monitoring. The experiments are based on four solenoid valves, similar to the ones used in nuclear power plants. The analyses based on the experimental data using two algorithms, i.e., the Randomized Window Decomposition (RWD) algorithm and the particle filtering algorithm, and the results are introduced in the report. The Big Data framework developed in this project can be used as a support tool in daily activities of plant operation and maintenance and will reduce current costs while maintaining or improving safety levels. Overall, the project will not only benefit existing reactors, however it will open new frontiers to realize the long overdue value of Big Data Analytics in the nuclear sphere.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2020

The Manufacturing Data and Machine Learning Platform: Enabling Real-time Monitoring and Control of Scientific Experiments via IoT

IoT devices and sensor networks present new opportunities for measuring, monitoring, and guiding scientific experiments. Sensors, cameras, and instruments can be combined to provide previously unachievable insights into the state of ongoing experiments. However, IoT devices can vary greatly in the type, volume, and velocity of data they generate, making it challenging to fully realize this potential. Indeed, synergizing diverse IoT data streams in near-real time can require the use of machine learning (ML). In addition, new tools and technologies are required to facilitate the collection, aggregation, and manipulation of sensor data in order to simplify the application of ML models and in turn, fully realize the utility of IoT devices in laboratories. Here we will demonstrate how the use of the Argonne-developed Manufacturing Data and Machine Learning (MDML) platform can analyze and use IoT devices in a manufacturing experiment. MDML is designed to standardize the research and operational environment for advanced data analytics and AI-enabled automated process optimization by providing the infrastructure to integrate AI in cyber-physical systems for in situ analysis. We will show that MDML is capable of processing diverse IoT data streams, using multiple computing resources, and integrating ML models to guide an experiment.

Machine Learning↗

NASA NTRS1983

Ablative thermal protection systems

The procedures used to establish the TPS (thermal protection system) design of the SRB (solid rocket booster) element of the Space Shuttle vehicle are discussed. A final evaluation of the adequacy of this design will be made from data obtained from the first five Shuttle flights. Temperature sensors installed at selected locations on the SRB structure covered by the TPS give information as a function of time throughout the flight. Anomalies are to be investigated and computer design thermal models adjusted if required. In addition, the actual TPS ablator material loss is to be measured after each flight and compared with analytically determined losses. The analytical methods of predicting ablator performance are surveyed.

Vaniman, J.↗

NASA NTRS1992

Acquisition, pointing and tracking performance of the Hubble Space Telescope fine guidance sensors

The three fine guidance sensors (FGSs) on board the HST have been operated extensively since the observatory was launched in April, 1990. The FGSs, each capable of measuring angles as small as 0.003 arcsec, provide required fine pointing information to the HST's pointing control system and are intended to serve as astrometry instruments. On-orbit data have shown that the acquisition, pointing and tracking performance of the FGSs in most cases meets, and of these sometimes exceeds, requirements. The versatility of the FGS digital control electronics to adapt to the unexpected conditions imposed on the sensors by the telescope spherical aberration and by solar panel jitter is discussed. There is encouragement from both on-orbit tests and analytical studies that the FGSs can accommodate the current telescope characteristics. Improvements to guide star acquisitions within the FGSs and to target acquisitions within science instruments have been accomplished with the internal distortion calibration of each FGS and with the alignment calibration between sensors. Techniques used in the calibration process and the resulting improvements in acquisitions are presented.

Eaton, David J.↗

DOE OSTI2021

Generalization Equations for Machine Learners Based on Physical and Abstract Laws

The physical and abstract laws derived from the first principles have been recently exploited to customize and sharpen machine learning (ML) methods and also derive their generalization equations. These laws often encapsulate knowledge that complements datasets and ML models. We present a generic framework that uses these laws to provide ML codes that are transferable across multiple areas, including data transport infrastructures and thermal hydraulics analytics of nuclear reactors. By anchoring on datasets from these areas and the statistical generalization theory, we present a rigorous approach to co-develop ML solutions and the generalization equations that characterize them, by exploiting the structure and constraints from the laws. We present illustrative examples using practical problems from existing literature on the performance characterization of data transport infrastructures, and the sensor error and power level estimation in nuclear reactor systems using sensor measurements of primary and secondary coolant systems, respectively.

Rao, Nageswara↗

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 ↗