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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 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Expanding the range of the resolvable strain from distributed fiber optic sensors using a local adaptive reference approach

Optical frequency domain reflectometry (OFDR) is a spectral measurement technique in which shifts in the local Rayleigh backscatter spectra can be used to perform distributed temperature or strain measurements relative to a reference measurement using ordinary single-mode optical fibers. Here, we demonstrate a data processing methodology for improving the resolvable range of temperature and strain by adaptively varying the reference measurement position by position, based on the time evolution of the local optical intensities and the correlation between the reference and active measurements. These methods nearly double the resolvable range of temperature and strain compared with that achieved using the traditional static reference approach.

47 OTHER INSTRUMENTATION↗
DOE OSTI2024

SSTDR and FDR Detection of Un-Energized and Energized Cable Anomalies Including Thermal Degradation Using Machine Learning

Historically, cables are initially qualified for nuclear power plant use for 40 years. As plants extend their operating license to 60 and 80 years, continued use of these cables must shift to a performance-based approach since it is cost prohibitive to completely replace cables that are likely still capable of performing their design function. A variety of cable tests are available and are commonly applied during outages when the cables can be taken out of service. Frequency domain reflectometry (FDR) is one of these test methods that is being more broadly accepted and used because it not only detects anomalies along the cable with a low-voltage signal that does not stress the cable insulation, but the technique also locates the anomalies. This supports follow-up local inspection and local repair or partial replacement of a damaged cable segment. Currently, FDR testing is only applied to cables that are taken out of service since the test instrument would be damaged by operational voltages.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Nickel-incorporated Oxide Composites for Fiber-Optic Based Gas Sensing

Numerous high-value applications within the energy sector involve environmental conditions that are incompatible with traditional sensor technology due to degradation of electrical interconnects, packaging, or the sensors themselves. These can include chemically harsh conditions, high temperature operation, or the presence of electromagnetic interference due to high voltage. The fiber optic platform, constructed of robust, electrically insulating glass or single crystal oxides, offers a versatile and often low cost per node solution to this problem, especially with the integration of distributed sensing techniques such as optical time-domain and frequency-domain reflectometry (OTDR, OFDR). A major challenge of gas and chemical sensing on the optical fiber platform is the fabrication of robust and stable sensing materials that interact quickly and reversibly to the presence of the target analytes. In this work, we discuss the utilization of nickel-incorporated oxides on evanescent-field optical fiber sensors for gas sensing under harsh conditions relevant to multiple energy infrastructure applications. This paper will discuss a Ni/GDC (Ni / Gd-doped ceria) based sensing layer targeting conditions relevant for high-temperature (up to at least 800 oC) hydrogen sensing applications (e.g., for operation within a solid oxide fuel cell or electrolyzer). The impact of hydrogen at elevated temperatures on the optical properties of Ni/GDC will be shown and the material mechanisms for the optical response will be discussed.

gas sensors↗
DOE OSTI2025

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

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

fiber optic sensors↗
DOE OSTI2025

Novel High Resolution High Temperature In-Line Sensors for Steel Manufacturing

To support efficiency, productivity, yield improvements, and future industry 4.0 and SMART manufacturing objectives for a competitive and prosperous steel industry, this program has embarked on an effort to develop, demonstrate and deploy several novel sensing technologies based on fiber optics for use in production steel facilities. Over the duration of this program, our team has successfully demonstrated three of these technologies: (1) near continuous Rayliegh Scattering optical frequency domain reflectometry (OFDR) sensing with single mode silica fibers for temperature sensing to 700 C, (2) semi-distributed fiber Bragg grating (FBG) sensing with multimode sapphire fibers for temperature sensing to >1600 C, and (3) remote in-situ Raman analysis for slag and flux chemistry analysis at steelmaking temperatures >1550 C. Each of these sensor and interrogation systems was developed, refined, and tested in our labs at Missouri S&T and then successfully deployed at SSAB’s production facilities at two sites, one in Montpelier, IA and one in Mobile, AL.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Development of High-Temperature Bonding Techniques to Enable High-Temperature Static or Dynamic Strain Measurements

Current light-water nuclear reactors rely on a variety of different sensors and sensor applications to meet their structural health monitoring needs throughout the entirety of the reactor primary, secondary, and containment systems. Optical fiber–based sensor technologies could provide solutions to reduce the sensor system footprint while enhancing the measurement fidelity and spatial resolution by leveraging distributed monitoring techniques. Moreover, advanced reactors may require optical fiber–based sensors for structural health monitoring because their operating temperatures will exceed the limits of conventional transducers used to acquire dynamic strain or acoustic data in nuclear power plants. Therefore, this report describes experiments targeting the development of high-temperature bonding techniques that would allow for potentially long lengths of fibers to be bonded to metallic reactor components in advanced reactor systems. The high temperatures experienced within target application, next-generation nuclear reactors, necessitate a high-temperature resistant bond to limit the amount of tension on the fiber at the target application temperature. The primary bonding method investigated in this work is brazing; hot-rolling has also been investigated to a lesser extent. Both techniques are well-suited to bonding optical fibers to large reactor components such as primary coolant piping, pressure vessels, or heat exchangers. Optical frequency domain reflectometry was used to monitor the strain in metal-coated optical fibers before, during, and after the high-temperature bonding process. On select optical fibers that were successfully bonded, additional thermal cycling was performed to assess the extent to which the fiber remained bonded based on the expected thermal expansion of the test specimen material. The results of the various experiments yielded the following general conclusions: (1) brazing is a viable technique for bonding and allows significant compressive strain to be applied to the fiber at room temperature; (2) hot-rolling is a viable technique as well, which has been more optimized than the brazing technique for bonding, but less residual compressive strain has been observed with this technique; and (3) both techniques will need further development and optimization to demonstrate bonding of a long length of fiber that can provably operate at relevant temperatures for an advanced nuclear reactor application.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Embedding of Optical Fibers with Electric Field Assisted Sintering

The Electric Field Assisted Sintering (EFAS) technique was used for embedding the fibers, involving rapid heating via an electric current and pressure, reducing fiber exposure to high temperatures. Stainless steel guide tubes were inserted at the fiber-matrix junctions to prevent fiber breakage during the sintering process. The study varied key EFAS parameters—temperature (800°C to 980°C), pressure (40-50 MPa), and hold time (5-10 minutes)—to assess how they influenced fiber embedding. After embedding, the fibers were inspected using optical frequency domain reflectometry (OFDR) to evaluate optical losses and strain along the fiber length. The OFDR scans confirmed that the fibers remained intact, and subsequent transmission tests demonstrated no macroscopic fractures. The embedded samples were also analyzed using scanning electron microscopy (SEM) and X-ray computed tomography (CT) scans. These tests confirmed good bonding between the fiber and matrix with no cracking, though some porosity was present in samples fabricated at lower temperatures. At higher temperatures (980°C), the fiber-matrix bonding was continuous and defect-free, with metal coatings aiding in the bonding process. Elemental analysis showed interdiffusion between the fiber coatings and matrix materials, particularly between the gold coating and stainless steel. Helium leak tests revealed that lower sintering temperatures resulted in matrix porosity, causing leaks, but samples fabricated at 980°C were leak-tight.

46 - INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AN↗
DOE OSTI2022

The Thermal Response of a Packed Bed Thermal Energy Storage System upon Saturated Steam Injection Using Distributed Temperature Sensing

The effectiveness of a thermal energy storage (TES) system is typically characterized with the help of thermal stratification or temperature gradients along the direction of heat injection, which is typically the flow direction of heat transfer fluid. The steepness of temperature gradients are a direct indicator of the effectiveness or efficiency of the heat storage or dispatch process. The temperature gradient evolution along the packed bed of ceramic particles upon saturated steam injection is presented in this work. Distributed temperature sensing based on optical frequency domain reflectometry was deployed in a packed bed of ceramic particles to capture the thermal front evolution in the axial direction. The physical processes accompanying steam injection in packed beds are complex due to phase change, transitioning two-phase flow, and changes in condensate accumulation. Therefore, the variation of thermal response of the TES system for various steam injection flow rates was experimentally studied using a high-resolution distributed temperature sensing system in a chemically inert alumina particle-packed bed. Distinct zones of different heat transfer modes were observed during the steam injection experiments. A distinct conduction zone, evident from diffuse thermal fronts, was observed at low flow rates, and these thermal gradients became sharper as the flow rate increased. The diffuse thermal fronts in the heat storage media suggest a low exergy efficiency of the TES system, as energy losses started initiating before a significant fraction of the bed was saturated with steam.

25 ENERGY STORAGE↗
DOE OSTI2025

Nickel-incorporated Oxide Composites for Fiber-Optic Based Gas Sensing

Numerous high-value applications within the energy sector involve environmental conditions that are incompatible with traditional sensor technology due to degradation of electrical interconnects, packaging, or the sensors themselves. These can include chemically harsh conditions, high temperature operation, or the presence of electromagnetic interference due to high voltage. The fiber optic platform, constructed of robust, electrically insulating glass or single crystal oxides, offers a versatile and often low cost per node solution to this problem, especially with the integration of distributed sensing techniques such as optical time-domain and frequency-domain reflectometry (OTDR, OFDR). A major challenge of gas and chemical sensing on the optical fiber platform is the fabrication of robust and stable sensing materials that interact quickly and reversibly to the presence of the target analytes. In this work, we discuss the utilization of nickel-incorporated oxides on evanescent-field optical fiber sensors for gas sensing under harsh conditions relevant to multiple energy infrastructure applications. This paper will discuss a Ni/GDC (Ni / Gd-doped ceria) based sensing layer targeting conditions relevant for high-temperature (up to at least 800oC) hydrogen sensing applications (e.g., for operation within a solid oxide fuel cell or electrolyzer). The impact of hydrogen at elevated temperatures on the optical properties of Ni/GDC will be shown and the material mechanisms for the optical response will be discussed.

gas sensors↗
DOE OSTI2025

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

Distributed fiber optic sensing is a cutting-edge technology that has found extensive applications in the monitoring of Ensuring the safety, integrity, and operational efficiency of underground product pipelines is vital for maintaining the nation’s critical infrastructure. Monitoring parameters such as hoop strain, pressure, and acoustic vibrations is key to detecting potential leaks, intrusions, or structural issues. Distributed optical fiber sensor (DOFS) systems provide a compelling solution for continuous, real-time monitoring over long distances. This paper details the development and pilot-scale implementation of DOFS systems for underground pipeline monitoring, evolving from a proof-of-concept stage. Multiple custom-designed DOFS interrogator units—such as optical frequency-domain reflectometry (OFDR), Brillouin optical time-domain analysis (BOTDA), and multimodal interferometer-based fiber acoustic sensors—were employed to measure key parameters like hoop strain, pressure, and acoustic vibrations. The underground product pipeline's outer diameter is 30 inches, the wall thickness is 1.28 inches, and the 3-foot depth. The fiber deployment strategies, and sensing data acquisition methods for these systems are discussed. The results demonstrate the effectiveness of DOFS in detecting hoop strain, temperature changes, and acoustic vibrations, showcasing their potential for real-time monitoring and enhancing pipeline safety.

distributed fiber sensing↗
DOE OSTI2021

Graphical Optimization of Spectral Shift Reconstructions for Optical Backscatter Reflectometry

Optical backscatter reflectometry (OBR) is an interferometric technique that can be used to measure local changes in temperature and mechanical strain based on spectral analyses of backscattered light from a singlemode optical fiber. The technique uses Fourier analyses to resolve spectra resulting from reflections occurring over a discrete region along the fiber. These spectra are cross-correlated with reference spectra to calculate the relative spectral shifts between measurements. The maximum of the cross-correlated spectra—termed quality—is a metric that quantifies the degree of correlation between the two measurements. Recently, this quality metric was incorporated into an adaptive algorithm to (1) selectively vary the reference measurement until the quality exceeds a predefined threshold and (2) calculate incremental spectral shifts that can be summed to determine the spectral shift relative to the initial reference. Using a graphical (network) framework, this effort demonstrated the optimal reconstruction of distributed OBR measurements for all sensing locations using a maximum spanning tree (MST). By allowing the reference to vary as a function of both time and sensing location, the MST and other adaptive algorithms could resolve spectral shifts at some locations, even if others can no longer be resolved.

47 OTHER INSTRUMENTATION↗
DOE OSTI2020

A metal-ceramic coaxial cable with multipoint Fabry-Pérot interferometers for monitoring distributed high temperature

A metal ceramic coaxial cable (MCCC) sensor containing multiple Fabry-Pérot interferometers (FPIs) has been designed, fabricated, and evaluated for measuring distributed high temperatures. The MCCC sensor demonstrated here consists of stainless steel tube and wire conductors, alumina tube insulator, and three pairs of air gap reflectors distributed along the cable. The multipoint sensor operation is realized by the joint time-frequency domain technique, which combines the functions of time-domain reflectometry and frequency division multiplexing to enable the measurement of spatially distributed temperature. The 3-point MCCC-FPI sensor has been demonstrated for distributed temperature measurements between 250 and 550 °C and operability up to 1000 °C. The sensor offers high sensitivity of >0.18 MHz/°C with a measurement resolution of 1 Hz and reasonably small high temperature measurement error range of ±3 °C.

42 ENGINEERING↗
DOE OSTI2022

Surface Wave Based Non-conductor-contact Reflectometry Method for Insulation and Jacket Damage Detection in Multi-Conductor Cables

This paper presents a non-conductor-contact surface wave reflectometry technique to locate insulation and jacket damage on multi-conductor cables at a distant location from the sensor. Simulation studies were conducted using Ansys high frequency structure simulator (HFSS). A GHz range surface wave launcher was employed such that maximum surface wave energies were confined in the insulation layer while minimizing attenuation. The wave launcher can potentially be mounted on the outer surface of live cables or cable conduits and requires no physical connection to the conductors. Multiple simulations involving a 4 GHz wave launcher and a three-conductor cable with an 8 mm outer diameter were carried out demonstrating the efficacy of the proposed method. Water leak and different types of insulation/jacket damage were simulated and detected.

reflectometry, multi-conductor cable, frequency do↗
DOE OSTI2022

Effect of Semiconducting Layer on Cable Insulation Damage Detection Using Surface Wave Reflectometry

This paper presents a study of the effect of the semiconducting layer present in medium and high voltage cables on surface wave propagation and its feasibility in detecting insulation damage on cables. Simulation studies were conducted using Ansys High Frequency Structure Simulator (HFSS). It was observed that attenuation increased with thicker semiconducting layer and higher conductivity of the layer. For instance, on a 24.4 mm diameter power cable, the electric field strength associated with a 1 GHz surface wave declines with distance and fades away after 30 m when a 2 mm thick semiconducting layer is present. More results as a function of semiconducting layer thickness, material conductivity and permittivity, distance of a damaged section, etc. will be presented.

reflectometry, unshielded power cable, semiconduct↗
DOE OSTI2024

Distributed strain sensing using Bi-metallic coated fiber optic sensors embedded in stainless steel

Silica fiber optic sensors are resistant to corrosive environments and high temperatures, making them attractive candidates for harsh conditions found in nuclear and aerospace industries. Moreover, fibers can be deployed remotely for continuous measuring of spatially distributed temperatures and strains. Here, this study investigated embedding a Ni/Cu bi-metallic coated fiber in a stainless-steel 316 (SS316) matrix using laser powder bed fusion towards functionalizing metal components for site-specific health monitoring. The embedded fiber was continuously interrogated during controlled heating to 1000°C. The measured fiber strains were similar to the expected differential thermal strains between the fiber and the SS316 matrix, until divergent behavior was observed at temperatures >500°C. No debonding at the matrix–coating–fiber interfaces was observed during microscopy, but significant interactions between the coatings and matrix resulted in diffusion-driven chemistry variations and Kirkendall void formation. Applying the strain-lag theory revealed plastic behavior in the Ni coating at temperatures >500°C, limiting the strain transfer to the fiber at higher temperatures. It was estimated that the elastic modulus in the Ni coating had decreased from ~200 GPa at room temperature to below 40 GPa, starting at 600°C. The low elastic modulus above 600°C is within the margin of what the tangent modulus would be in the case of bilinear isotropic hardening. Regardless of the divergent strain transfer at higher temperatures, the fiber was exposed to the equivalent of 1.9 % engineering strain at 1000°C, but measured only a 0.7 % engineering strain due to the poor strain transfer. Although compensating for the plastic behavior of Ni proved challenging, the bonding of a brittle silica fiber to a metal matrix surviving to 1000°C invites potential iterations on coating material for future application. For example, the embedded fiber is sufficient for acoustic energy transfer, realizing high temperature distributed acoustic sensing.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Dopant, coating, and grating effects in silica optical fibers under extreme neutron irradiation

Radiation effects on fiber Bragg gratings (FBGs) have been studied but data gaps related to the effects of displacement damage resulting from high fast neutron fluence remain. In this work, Type-I and Type-II FBGs inscribed in optical fibers with various core dopants (Ge and F) and fiber coatings (acrylate, polyimide) were monitored in situ during 75 days of neutron irradiation to a peak fast (>0.1 MeV) neutron fluence of 3 X 10 21 n fast /cm 2 . Further, the reflected intensity of the Type-I FBGs inscribed in a Ge-doped core fiber decreased by > 30 dB within 7 h of irradiation (10 19 n fast /cm 2 ), whereas Type-II FBGs inscribed in a pure silica core fiber eventually approached >40 dB attenuation after accumulating a fast neutron fluence on the order of 10 20 n fast /cm 2 . Type-II FBGs inscribed in F-doped core fiber improved stability: the attenuation approached an equilibrium value in the range of 10 to 20 dB.

47 OTHER INSTRUMENTATION↗
DOE OSTI2021

Distributed Acoustic Sensing Based on Coherent Microwave Photonics Interferometry

A microwave photonics method has been developed for measuring distributed acoustic signals. This method uses microwave-modulated low coherence light as a probe to interrogate distributed in-fiber interferometers, which are used to measure acoustic-induced strain. By sweeping the microwave frequency at a constant rate, the acoustic signals are encoded into the complex microwave spectrum. The microwave spectrum is transformed into the joint time–frequency domain and further processed to obtain the distributed acoustic signals. The method is first evaluated using an intrinsic Fabry Perot interferometer (IFPI). Acoustic signals of frequency up to 15.6 kHz were detected. The method was further demonstrated using an array of in-fiber weak reflectors and an external Michelson interferometer. Two piezoceramic cylinders (PCCs) driven at frequencies of 1700 Hz and 3430 Hz were used as acoustic sources. The experiment results show that the sensing system can locate multiple acoustic sources. The system resolves 20 nε when the spatial resolution is 5 cm. The recovered acoustic signals match the excitation signals in frequency, amplitude, and phase, indicating an excellent potential for distributed acoustic sensing (DAS).

47 OTHER INSTRUMENTATION↗