Results for “Optical data fusion” — Page 3

DOE OSTI2021

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.

36 MATERIALS SCIENCE↗

NASA NTRSDate not supplied

Assessment of Segmentation-Induced Deviations of Porosity Metrics in Powder Bed Fusion Additively Manufactured Components

Post processing X-ray computational tomography (CT) inspection data for additively manufactured (AM) components can induce deviations in defect quantification, affecting subsequent fatigue and failure predictions. To assess the influence and potential impact of segmentation-induced measurement deviations, this paper applies several segmentation techniques to X-ray CT data for powder bed fusion Ti-6Al-4V specimens exhibiting porosity conditions. X-ray CT reconstructions were segmented with varying techniques including Otsu’s thresholding, random forest, k-nearest neighbors, and the multilayer perceptron. Metrics such as pore size and global porosity were compared for internal validity. Then, top-down X-ray CT measurements of surface-breaking porosity were compared to optical profilometry for cross-validation.

Data fusion↗

DOE OSTI2023

System and method to fuse multiple sources of optical data to generate a high-resolution, frequent and cloud-/gap-free surface reflectance product

Aspects of the subject disclosure may include, for example, performing, by a processing system, image fusion using two or more groups of images to generate predicted images, wherein each group of the two or more groups has one of a different resolution, a different frequency temporal pattern or a combination thereof than another of the two or more groups. Gap filling can be performed by the processing system to correct images of the two or more groups. Additional embodiments are disclosed.

Guan, Kaiyu↗

NASA NTRSDate not supplied

A14H-04 Analysis of Simulated and Observed Trends in Global Surface PM2.5 and Aerosol Optical Properties from 1958 to 2018 Using the NASA GEOSCCM

Modeling of long-term trends of aerosols and their properties is important for constraining aerosol-climate forcing, and for characterizing changes in particulate matter pollution speciation and exposure. Here we study global and regional long-term trends in surface fine particulate matter (PM ) and aerosol optical properties for 60 years from 1958 to 2018, using simulations performed with the NASA Goddard Earth Observing System Chemistry Climate Model (GEOSCCM), and evaluate the model hindcast with observations for the last three decades. Comparing the modeled aerosols with a diverse set of observations helps interpret observed and simulated trends, and serves as a benchmark for future GEOSCCM developments and input datasets improvements. We first characterize modeled global and regional temporal changes in surface PM and its components, aerosol optical depth (AOD) and single scattering albedo (SSA) and we interpret their link with emissions drivers. We then compare modeled surface PM with ground-based observations from monitoring networks and with global reconstructed PM datasets from observations-model data fusion. Total AOD is compared with long-term satellite measurements from the Moderate Resolution Imaging Spectroradiometer (MODIS) and measurements from the ground-based Aerosol Robotic Network (AERONET). Additional aerosol optical properties, such as absorption and scattering coefficients, are evaluated with ground-based observations from the Global Atmosphere Watch (GAW) records.

aerosols↗

DOE OSTI2026

A novel method for thermal noise reduction, enabling measurements of broadband, low-amplitude electron temperature fluctuations using individual radiometer channels

A new analysis method has been developed for measurements of broadband, low-amplitude turbulent electron temperature fluctuations in fusion plasmas using individual radiometer channels of a correlation electron cyclotron emission diagnostic. This method takes advantage of differences in the correlation time of thermal noise compared to the correlation time of plasma fluctuations in fusion reactors. The validation of this single-channel method is demonstrated using comparisons with the standard dual-channel radiometer spectral decorrelation method for measurements of turbulent electron temperature fluctuations in the core and edge of low confinement (L), improved confinement (I), and high confinement (H)-mode plasmas at the ASDEX Upgrade tokamak.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS2000

Fusion of AIRSAR and TM Data for Parameter Classification and Estimation in Dense and Hilly Forests

The expanded remotely sensed data space consisting of coincident radar backscatter and optical reflectance data provides for a more complete description of the Earth surface. This is especially useful where many parameters are needed to describe a certain scene, such as in the presence of dense and complex-structured vegetation or where there is considerable underlying topography. The goal of this paper is to use a combination of radar and optical data to develop a methodology for parameter classification for dense and hilly forests, and further, class-specific parameter estimation. The area to be used in this study is the H. J. Andrews Forest in Oregon, one of the Long-Term Ecological Research (LTER) sites in the US. This area consists of various dense old-growth conifer stands, and contains significant topographic relief. The Andrews forest has been the subject of many ecological studies over several decades, resulting in an abundance of ground measurements. Recently, biomass and leaf-area index (LAI) values for approximately 30 reference stands have also become available which span a large range of those parameters. The remote sensing data types to be used are the C-, L-, and P-band polarimetric radar data from the JPL airborne SAR (AIRSAR), the C-band single-polarization data from the JPL topographic SAR (TOPSAR), and the Thematic Mapper (TM) data from Landsat, all acquired in late April 1998. The total number of useful independent data channels from the AIRSAR is 15 (three frequencies, each with three unique polarizations and amplitude and phase of the like-polarized correlation), from the TOPSAR is 2 (amplitude and phase of the interferometric correlation), and from the TM is 6 (the thermal band is not used). The range pixel spacing of the AIRSAR is 3.3m for C- and L-bands and 6.6m for P-band. The TOPSAR pixel spacing is 10m, and the TM pixel size is 30m. To achieve parameter classification, first a number of parameters are defined which are of interest to ecologists for forest process modeling. These parameters include total biomass, leaf biomass, LAI, and tree height. The remote sensing data from radar and TM are used to formulate a multivariate analysis problem given the ground measurements of the parameters. Each class of each parameter is defined by a probability density function (pdf), the spread of which defines the range of that class. High classification accuracy results from situations in which little overlap occurs between pdfs. Classification results provide the basis for the future work of class-specific parameter estimation using radar and optical data. This work was performed in part by the Jet Propulsion Laboratory, California Institute of Technology, Pasadena, CA, and in part by the NASA Ames Research Center, Moffett Field, CA, both under contract from the National Aeronautics and Space Administration.

Moghaddam, Mahta↗

DOE OSTI2024

Sub-millisecond keyhole pore detection in laser powder bed fusion using sound and light sensors and machine learning

Laser powder bed fusion is a mainstream additive manufacturing technology widely used to manufacture complex parts in prominent sectors, including aerospace, biomedical, and automotive industries. However, during the printing process, the presence of an unstable vapor depression can lead to a type of defect called keyhole porosity, which is detrimental to the part quality. In this study, we developed an effective approach to locally detect the generation of keyhole pores during the printing process by leveraging machine learning and a suite of optical and acoustic sensors. Simultaneous synchrotron x-ray imaging allows the direct visualization of pore generation events inside the sample, offering high-fidelity ground truth. A neural network model adopting SqueezeNet architecture using single-sensor data was developed to evaluate the fidelity of each sensor for capturing keyhole pore generation events. Our comparative study shows that the near infrared images gave the highest prediction accuracy, followed by 100 kHz and 20 kHz microphones, and the photodiode sensitive to processing laser wavelength had the lowest accuracy. Using a single sensor, over 90% prediction accuracy can be achieved with a temporal resolution as short as 0.1 ms. A data fusion scheme was also developed with features extracted using SqueezeNet neural network architecture and classification using different machine learning algorithms. Our work demonstrates the correlation between the characteristic optical and acoustic emissions and the keyhole oscillation behavior, and thereby provides strong physics support for the machine learning approach.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Three-dimensional hot-spot x-ray emission tomography from cryogenic deuterium–tritium direct-drive implosions on OMEGA

A three-dimensional model of the hot-spot x-ray emission has been developed and applied to the study of low-mode drive asymmetries in direct-drive inertial confinement fusion implosions on OMEGA with cryogenic deuterium–tritium targets. Here, the steady-state model assumes an optically thin plasma and the data from four x-ray diagnostics along quasi-orthogonal lines of sight are used to obtain a tomographic reconstruction of the hot spot. A quantitative analysis of the hot-spot shape is achieved by projecting the x-ray emission into the diagnostic planes and comparing this projection to the measurements. The model was validated with radiation-hydrodynamic simulations assuming a mode-2 laser illumination perturbation resulting in an elliptically shaped hot spot, which was accurately reconstructed by the model using synthetic x-ray images. This technique was applied to experimental data from implosions in polar-direct-drive illumination geometry with a deliberate laser-drive asymmetry, and the hot-spot emission was reconstructed using spherical-harmonic modes of up to ℓ = 3. A 10% stronger drive on the equator relative to that on the poles resulted in a prolate-shaped hot spot at stagnation with a large negative A 2,0 coefficient of A 2,0 = –0.47 ± 0.03, directly connecting the modal contribution of the hot-spot shape with the modal contribution in laser-drive asymmetry.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2024

3D Reconstruction of a High-Energy Diffraction Microscopy Sample Using Multi-modal Serial Sectioning with High-Precision EBSD and Surface Profilometry

High-energy diffraction microscopy (HEDM) combined with in situ mechanical testing is a powerful nondestructive technique for tracking the evolving microstructure within polycrystalline materials during deformation. This technique relies on a sophisticated analysis of X-ray diffraction patterns to produce a three-dimensional reconstruction of grains and other microstructural features within the interrogated volume. However, it is known that HEDM can fail to identify certain microstructural features, particularly smaller grains or twinned regions. Characterization of the identical sample volume using high-resolution surface-specific techniques, particularly electron backscatter diffraction (EBSD), can not only provide additional microstructure information about the interrogated volume but also highlight opportunities for improvement of the HEDM reconstruction algorithms. In this study, a sample fabricated from undeformed “low solvus, high refractory” nickel-based superalloy was scanned using HEDM. The volume interrogated by HEDM was then carefully characterized using a combination of surface-specific techniques, including epi-illumination optical microscopy, zero-tilt secondary and backscattered electron imaging, scanning white light interferometry, and high-precision EBSD. Custom data fusion protocols were developed to integrate and align the microstructure maps captured by these surface-specific techniques and HEDM. The raw and processed data from HEDM and serial sectioning have been made available via the Materials Data Facility (MDF) at https://doi.org/10.18126/4y0p-v604 for further investigation.

36 MATERIALS SCIENCE↗

NASA NTRS2007

Orbit Determination of LEO Satellites for a Single Pass through a Radar: Comparison of Methods

The problem of determining the orbit of a space object from measurements based on one pass through the field of view of a radar is not a new one. Extensive research in this area has been carried out in the USA and Russia since the late 50s when these countries started the development of ballistic missile defense (BMD) and Early Warning systems. In Russia these investigations got additional stimulation in the early 60s after the decision to create a Space Surveillance System, whose primary task would be the maintenance of the satellite catalog. These problems were the focus of research interest until the middle 70s when the appropriate techniques and software were implemented for all radars. Then for more than 20 years no new research papers appeared on this subject. This produced an impression that all the problems of track determination based on one pass had been solved and there was no need for further research. In the late 90s interest in this problem arose again in relation to the following. It was estimated that there would be greater than 100,000 objects with size greater than 1-2 cm and collision of an operational spacecraft with any of these objects could have catastrophic results. Thus, for prevention of hazardous approaches and collisions with valuable spacecraft the existing satellite catalog should be extended by at least an order of magnitude This is a very difficult scientific and engineering task. One of the issues is the development of data fusion procedures and the software capable of maintaining such a huge catalog in near real time. The number of daily processed measurements (of all types, radar and optical) for such a system may constitute millions, thus increasing the number of measurements by at least an order of magnitude. Since we will have ten times more satellites and measurements the computer effort required for the correlation of measurements will be two orders of magnitude greater. This could create significant problems for processing data close to real time even for modern computers. Preliminary "compression" of data for one pass through the field of view of a sensor can significantly reduce the requirements to computers and data communication. This compression will occur when all the single measurements of the sensor are replaced by the orbit determined on their basis. The single measurement here means the radar parameters (range, azimuth, elevation, and in some cases range rate) measured by a single pulse.

Khutorovsky, Z.↗

DOE OSTI2022

Novel design for a polarizing DUV spectrometer using a Wollaston prism and its application as a diagnostic for measuring Thomson scattering data in the presence of strong self-emission backgrounds

We present a novel design for an optical spectrometer for use in ultraviolet Thomson scattering measurements of plasma parameters in high energy density (HED) inertial confinement fusion experiments on large-scale high-energy laser facilities. In experiments investigating high-Z plasmas, the fidelity of measurements is commonly limited by signal/background ratios approaching or exceeding unity. An alpha barium borate Wollaston prism can provide both spectral dispersion and polarization channel separation, allowing simultaneous measurement of both the Thomson scattering signal and plasma self-emission along a single line of sight and in a single experiment, which should greatly improve data quality and reduce the opportunity cost of taking high quality measurements. Here, we present a basic discussion of the design and a worked example of an instrument designed to take fourth harmonic electron plasma wave measurements in HED experiments at the OMEGA laser facility.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2024

Multi-phenomenology Yield Characterization

This report serves as the first delivery of a four-year applied science effort to transform and advance the error bounds for the yield estimate of an explosion. Each year’s delivery will be in this form, culminating in the submission of this work for peer review to a scientific journal. Importantly, the yearly progress reports can then also be viewed as expanding drafts working towards a formal journal article submission. For the first tranche of funding, we collaborated with Air Force Technical Applications Center (AFTAC) scientists to identify unclassified real-world data that demonstrate and validate our advanced error propagation methods. Collaboration includes visits to AFTAC and telecons. For this development, we illustrate the fusion of seismic, acoustic, optical, and surface effect signatures from an explosion. The mathematics and code being adapted to this specific application (Williams et al., 2021) involves physics models of multiple sensor signatures. We have also identified related physics models and have integrated them into code. Current methods of underground explosion yield estimation for the Threshold Test Ban Treaty (TTBT) have served the US treaty monitoring mission well for decades. A research objective of the Defense Nuclear Nonproliferation Research and Development (DNN R&D) office of the National Nuclear Security Administration (NNSA) has always been to provide new technical capabilities for monitoring lower thresholds. The general model and error propagation code to be developed in this project is based on significant advances in error modeling and propagation needed to analyze data at lower detection thresholds. The second tranche of funding for this project began on May 1, 2022, and planned work for the second tranche includes: i) completing the integration of physical model code into the general error model framework; this code accommodates a wide range of linear/nonlinear source models, fixed/ random effects, and frequentist/Bayesian analyses (the purpose of which is not to dictate to users how to analyze data, but instead to allow users the maximum flexibility in their work); ii) illustrative application of code to identified data, and; iii) initial planning with AFTAC researchers on delivery of code to the Common Development Environment at AFTAC, and continued writing of the planned final journal article submission (year two of this progress report), with particular emphasis on descriptions of data identified for this effort.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗

DOE OSTI2023

Overview and first measurements of the MAST Upgrade bolometer diagnostic

Here, a suite of multi-channel resistive bolometers has been implemented to measure the total radiation from Mega Amp Spherical Tokamak Upgrade plasmas, with cameras covering the core plasma and lower divertor chamber. Data are digitized and processed using novel field-programmable gate array-based electronics, offering improved compactness and new operational capabilities. A synthetic diagnostic has been developed to explore the quality of 2D reconstructions available from the system and to quantify the uncertainty on quantities such as the total radiated power. Measurements in the first campaign have demonstrated correct functioning of the diagnostic while also highlighting issues with electrical noise and some failure mechanisms of the detectors, as well as significant neutral beam fast-particle losses.

47 OTHER INSTRUMENTATION↗

NASA NTRS2002

Multi-Image Registration for an Enhanced Vision System

An Enhanced Vision System (EVS) utilizing multi-sensor image fusion is currently under development at the NASA Langley Research Center. The EVS will provide enhanced images of the flight environment to assist pilots in poor visibility conditions. Multi-spectral images obtained from a short wave infrared (SWIR), a long wave infrared (LWIR), and a color visible band CCD camera, are enhanced and fused using the Retinex algorithm. The images from the different sensors do not have a uniform data structure: the three sensors not only operate at different wavelengths, but they also have different spatial resolutions, optical fields of view (FOV), and bore-sighting inaccuracies. Thus, in order to perform image fusion, the images must first be co-registered. Image registration is the task of aligning images taken at different times, from different sensors, or from different viewpoints, so that all corresponding points in the images match. In this paper, we present two methods for registering multiple multi-spectral images. The first method performs registration using sensor specifications to match the FOVs and resolutions directly through image resampling. In the second method, registration is obtained through geometric correction based on a spatial transformation defined by user selected control points and regression analysis.

Hines, Glenn↗

DOE OSTI2020

ICME and In-Situ Process Monitoring for Rapid Qualification of Components Made by Laser-based Powder Bed Additive Manufacturing Processes for Nuclear Structural Applications

Additive manufacturing (AM) through selective powder bed melting of successive layers is being considered as disruptive technology for rapid production of low-cost nuclear reactor internal components with complex geometries. However, there is a potential for non-uniform distribution of physical features, such as porosity or microstructural differences, due to variations of temperature across a component build. These heterogeneities make the deployment of traditional material qualification and non-destructive evaluation of AM components difficult. This research project explored the feasibility of using in-situ process monitoring methods and integrated computational materials engineering (ICME) principles as an alternate qualification methodology and approach. This project included six individual tasks: (i) design of artifacts relevant to the nuclear power industry, (ii) evaluation of laser processing and in-situ measurements, (iii) computational modeling, (iv) ex-situ microstructural characterization, (v) evaluation of scaling the methodology for large-scale structures, and (vi) development of a data package to codes and standards organizations. As a part of this research, laser powder bed fusion of metals (316L, Alloy 718, and Ti6Al4V) was explored. This document provides an overview of the research performed over three years and serves as the final U.S. Department of Energy report for this project. In the third year, the project focused on the following activities: (a) in-situ infrared and optical imaging of each layer during processing of representative stainless steel geometries; (b) development of methodologies to analyze the data; and (c) application of ICME methodologies and other experiments to estimate the relevance of defects and microstructure to tensile properties.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2020

ICME and In-Situ Process Monitoring for Rapid Qualification of Components Made by Laser-based Powder Bed Additive Manufacturing Processes for Nuclear Structural Applications

Additive manufacturing (AM) through selective powder bed melting of successive layers is being considered as disruptive technology for rapid production of low-cost nuclear reactor internal components with complex geometries. However, there is a potential for non-uniform distribution of physical features, such as porosity or microstructural differences, due to variations of temperature across a component build. These heterogeneities make the deployment of traditional material qualification and non-destructive evaluation of AM components difficult. This research project explored the feasibility of using in-situ process monitoring methods and integrated computational materials engineering (ICME) principles as an alternate qualification methodology and approach. This project included six individual tasks: (i) design of artifacts relevant to the nuclear power industry, (ii) evaluation of laser processing and in-situ measurements, (iii) computational modeling, (iv) ex-situ microstructural characterization, (v) evaluation of scaling the methodology for large-scale structures, and (vi) development of a data package to codes and standards organizations. As a part of this research, laser powder bed fusion of metals (316L, Alloy 718, and Ti6Al4V) was explored. This document provides an overview of the research performed over three years and serves as the final U.S. Department of Energy report for this project. In the third year, the project focused on the following activities: (a) in-situ infrared and optical imaging of each layer during processing of representative stainless steel geometries; (b) development of methodologies to analyze the data; and (c) application of ICME methodologies and other experiments to estimate the relevance of defects and microstructure to tensile properties.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2020

ICME and In-Situ Process Monitoring for Rapid Qualification of Components Made by Laser-based Powder Bed Additive Manufacturing Processes for Nuclear Structural Applications

Additive manufacturing (AM) through selective powder bed melting of successive layers is being considered as disruptive technology for rapid production of low-cost nuclear reactor internal components with complex geometries. However, there is a potential for non-uniform distribution of physical features, such as porosity or microstructural differences, due to variations of temperature across a component build. These heterogeneities make the deployment of traditional material qualification and non-destructive evaluation of AM components difficult. This research project explored the feasibility of using in-situ process monitoring methods and integrated computational materials engineering (ICME) principles as an alternate qualification methodology and approach. This project included six individual tasks: (i) design of artifacts relevant to the nuclear power industry, (ii) evaluation of laser processing and in-situ measurements, (iii) computational modeling, (iv) ex-situ microstructural characterization, (v) evaluation of scaling the methodology for large-scale structures, and (vi) development of a data package to codes and standards organizations. As a part of this research, laser powder bed fusion of metals (316L, Alloy 718, and Ti6Al4V) was explored. This document provides an overview of the research performed over three years and serves as the final U.S. Department of Energy report for this project. In the third year, the project focused on the following activities: (a) in-situ infrared and optical imaging of each layer during processing of representative stainless steel geometries; (b) development of methodologies to analyze the data; and (c) application of ICME methodologies and other experiments to estimate the relevance of defects and microstructure to tensile properties.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2020

ICME and In-Situ Process Monitoring for Rapid Qualification of Components Made by Laser-based Powder Bed Additive Manufacturing Processes for Nuclear Structural Applications

Additive manufacturing (AM) through selective powder bed melting of successive layers is being considered as disruptive technology for rapid production of low-cost nuclear reactor internal components with complex geometries. However, there is a potential for non-uniform distribution of physical features, such as porosity or microstructural differences, due to variations of temperature across a component build. These heterogenities make the deployment of traditional material qualification and non-destructive evaluation of AM components difficult. This research project explored the feasibility of using in-situ process monitoring methods and integrated computational materials engineering (ICME) principles as an alternate qualification methodology and approach. This project included six individual tasks: (i) design of artifacts relevant to the nuclear power industry, (ii) evaluation of laser processing and in-situ measurements, (iii) computational modeling, (iv) ex-situ microstructural characterization, (v) evaluation of scaling the methodology for large-scale structures, and (vi) development of a data package to codes and standards organizations. As a part of this research, laser powder bed fusion of metals (316L, Alloy 718, and Ti6Al4V) was explored. This document provides an overview of the research performed over three years and serves as the final U.S. Department of Energy report for this project. In the third year, the project focused on the following activities: (a) in-situ infrared and optical imaging of each layer during processing of representative stainless steel geometries; (b) development of methodologies to analyze the data; and (c) application of ICME methodologies and other experiments to estimate the relevance of defects and microstructure to tensile properties.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗