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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Machine-Learning-Based Analysis of the Guy-Greenbrier, Arkansas Earthquakes: A Tale of Two Sequences

Here, we revisited the June 2010 to October 2011 Guy-Greenbrier earthquake sequence in central Arkansas using PhaseNet, a deep neural network trained to pick P and S arrival times. We applied PhaseNet to continuous waveform data and used phase association and hypocenter relocation to locate nearly 90,000 events. Our catalog suggests that the sequence consists of two adjacent earthquake sequences on the same fault and that the second sequence may be associated with the wastewater disposal well to the west of the Guy-Greenbrier Fault, rather than the wells to the north and the east that were previously implicated. We find that each sequence is composed of many small clusters that exhibit diffusion along the fault at shorter timescales. Our study demonstrates that machine-learning-based earthquake catalog development is now feasible and will yield new insights into earthquake behavior.

58 GEOSCIENCES↗
DOE OSTI2023

Transport Properties of Magnetized High-Energy Density Plasma (Final Project Report)

This report summarizes results of project DE-SC0016159 "Transport Properties of Magnetized High-Energy-Density Plasma,'' which ran from 7/15/2016 - 7/14/2021. The primary objectives of the work, as stated in the original proposal, were to develop a theory that describes transport coefficients in magnetized high energy density plasmas and to test the theory with molecular dynamics (MD) simulations. The science challenge is that strong ion coupling, strong magnetization of electrons, and partial degeneracy of electrons, cause the system to be in a regime that is not well described by current theory. The particular processes that were to be investigated include: ion stopping power, diffusion, electron-ion temperature relaxation, thermal conduction and viscosity. All of the primary research objectives were accomplished during the course of this work. In addition, some unexpected results were discovered along the way that led to new and productive research directions. This work resulted in 17 publications in well-respected peer-reviewed journals (primarily Physics of Plasmas and Physical Review E), and 2 more are being prepared for publication. A few of these were selected as Editor's Picks and one was published as a Rapid Communication. Highlights of the research results include: Transport phase space: The first identification of the parameter space that defines fundamental transport regimes in terms of the Coulomb coupling and magnetization parameters. Mean force kinetic theory: Systematic derivation of a kinetic theory for strongly coupled plasmas based on a new expansion parameter of the BBGKY hierarchy. This provided the derivation of a theory that we had previously posed phenomenologically, and also revealed a new term that captures the equation of state properties at all coupling strengths. Transverse friction force: Discovery that the friction force on a test charge in a strongly magnetized plasma includes a component that is perpendicular to the motion of the test charge in the plane defined by the velocity and magnetic field vectors. Gyrofriction force: Discovery that the friction force on a test charge in a plasma that is both strongly magnetized and strongly coupled includes a component of the force in the direction of the Lorentz force. Kinetic theory for warm dense matter: Extension of the mean force kinetic theory to include partial electron degeneracy, so that it applies to warm dense matter.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

Preliminary Transfer Learning Results on Israel Data

In this preliminary report, we use publicly available data recorded in Israel to test and expand upon existing machine learning models for seismic-phase detection and arrival-time measurement. We downloaded 3-years of waveform data from Geofon, and cross referenced the waveforms to Israel bulletin picks (Schardong et al., 2021). The initial results using existing models directly generated ubiquitous false detections and that obscured detections of signals that are clearly visible in the waveforms. However, after applying transfer learning (tuning parameters in the existing ML models using one year of the Israel-network data), the results are encouraging, i.e. ML picks agree within a few tenths of a second with bulletin picks and the number of false detections is greatly reduced. The bulletin picks are a good starting point, but they cannot be considered ground-truth. To test potential improvement in picking using ML we would like to relocate the events using the ML picks to see if the events cluster more tightly at known mine locations. However, in order to constrain event locations, we need ML picks for the whole Israeli-Jordanian network, which requires waveforms that are not publicly available.

58 GEOSCIENCES↗
DOE OSTI2022

Utah FORGE - Development of a Reservoir Seismic Velocity Model and Seismic Resolution Study

This is data from and a final report on the development of a 3D velocity model for the larger FORGE area and on the seismic resolution in the stimulated fracture volume at the bottom of well 16A-32. The velocity model was developed using RMS velocities of the seismic reflection survey and seismic velocity logs from borehole measurements as an input model. To improve the accuracy of the model in the shallow subsurface, travel times phase arrivals of the direct propagating P-waves were determined from the seismic reflection data, using PhaseNet, a deep-neural-network-based seismic arrival time picking method. The travel times were subsequently inverted using the input velocity model. The seismic resolution study used borehole and surface seismic sensors as well as the seismicity observed during the April 2022 stimulation experiment to estimate the seismic resolution in the activated fracture reservoir. The data contain a 3D P- and S-wave velocity model for the larger FORGE area.

15 GEOTHERMAL ENERGY↗
DOE OSTI2022

Orbital stability analysis of hypothetical Earth-mass and Luna-mass moons in the Sagarmatha (HD 100777) star system

Abstract Six of the solar system planets have 150 confirmed moons (Earth—1, Mars—2, Jupiter—53, Saturn—53, Uranus—27, Neptune—14) and seven of them (Ganymede, Titan, Callisto, Io, the Moon, Europa, Triton) have masses >0.001 $M_\oplus$. However, no exomoons have yet been discovered despite the successful detection of ∼5000 exoplanets. We can infer, based on the solar system planets, that these exoplanets are capable of hosting one or more exomoons. In this paper, we study the possible existence of hypothetical Earth-mass and Luna-mass moons orbiting the Jupiter-mass planet, Laligurans (HD 100777b) in the Sagarmatha (HD 100777) star system by means of orbital stability. We apply long-term orbital integrations and the MEGNO (mean exponential growth of nearby orbits) chaos indicator to study the orbital stability of the moons and predict a phase-space region comprising periodic, chaotic, and unstable orbits. The phase spaces primarily constitute the moon's semimajor axis, which extends from the host planet's Roche radius to the Hill radius, and full range of eccentricity. Specific points are picked from three different regions of the MEGNO map and run as single-orbit integration for up to 10 billion periods of the innermost orbit. Furthermore, the lifetime and maximum eccentricity maps are generated from the direct integration to inspect the stable and unstable orbital configurations. The analyses of these maps, with the aid of time-series plots, show that both moons maintain stable orbits in the low-eccentricity regime and semimajor axis between the Roche limit and 28.4% of the Hill radius of the planet.

Gautam, Aayush (ORCID:0000000247257589)↗
DOE OSTI2022

Multifidelity DRAM Simulation in SST [Poster]

We will always want to speed up simulation. While architects are able to pick between levels of detail when designing simulation, we will find further speed-up if we can adjust the level of detail during simulation, depending on the behavior of the simulated components. We create a simple fixed-latency model for each phase. On the first execution of a phase, we record the average latency of accesses. On subsequent executions, we skip DRAMSin 3 and send the response back using the average latency.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2025

Processability and Material Behavior of NiTi Shape Memory Alloys Using Wire Laser-Directed Energy Deposition (WL-DED)

Utilizing additive manufacturing (AM) techniques with shape memory alloys (SMAs) like NiTi shows great promise for fabricating highly flexible and functionally superior 3D metallic structures. Compared to methods relying on powder feedstocks, wire-based additive manufacturing processes provide a viable alternative, addressing challenges such as chemical composition instability, material availability, higher feedstock costs, and limitations on part size while simplifying process development. This study presented a novel approach by thoroughly assessing the printability of Ni-rich Ni55.94Ti (Wt. %) SMA using the wire laser-directed energy deposition (WL-DED) technique, addressing the existing knowledge gap regarding the laser wire-feed metal additive manufacturing of NiTi alloys. For the first time, the impact of processing parameters—specifically laser power (400–1000 W) and transverse speed (300–900 mm/min)—on single-track fabrication using NiTi wires in the WL-DED process was examined. An optimal range of process parameters was determined to achieve high-quality prints with minimal defects, such as wire dripping, stubbing, and overfilling. Building upon these findings, we printed five distinct cubes, demonstrating the feasibility of producing nearly porosity-free specimens. Notably, this study investigated the effect of energy density on the printed part density, impurity pick-up, transformation temperature, and hardness of the manufactured NiTi cubes. The results from the cube study demonstrated that varying energy densities (46.66–70 J/mm3) significantly affected the quality of the deposits. Lower to intermediate energy densities achieved high relative densities (>99%) and favorable phase transformation temperatures. In contrast, higher energy densities led to instability in melt pool shape, increased porosity, and discrepancies in phase transformation temperatures. These findings highlighted the critical role of precise parameter control in achieving functional NiTi parts and offer valuable insights for advancing AM techniques in fabricating larger high-quality NiTi components. Additionally, our research highlighted important considerations for civil engineering applications, particularly in the development of seismic dampers for energy dissipation in structures, offering a promising solution for enhancing structural performance and energy management in critical infrastructure.

Dabbaghi, Hediyeh↗
DOE OSTI2026

Constructing a High‐Resolution Aftershock Catalog for the 2017 Mw 8.2 Tehuantepec Earthquake Sequence Using a Machine Learning–Based Workflow

The 8 September 2017 Mw 8.2 Tehuantepec earthquake was the largest instrumentally recorded normal‐faulting earthquake in Mexico. The mainshock occurred offshore within the Tehuantepec seismic gap, generating >30,000 aftershocks in the following year. We applied an open‐source, machine learning (ML)–assisted workflow to construct a high‐resolution aftershock catalog using data from temporary and permanent seismic networks in southern Mexico. The workflow integrates PhaseNet for phase detection; GaMMA for phase association; and VELEST, HypoInverse, and HypoDD for velocity modeling and relocation. We processed seven months of continuous waveform data from 29 broadband stations, including a temporary rapid‐response deployment that improved station coverage of the offshore rupture zone. To evaluate performance, we compared our results against analyst‐reviewed picks and event locations from the Servicio Sismológico Nacional catalog. The resulting catalog contains 11,374 relocated earthquakes and represents the most comprehensive published dataset for this sequence, incorporating the first full use of the temporary network. Relocated hypocenters show improved depth control and align well with the Slab2.0 subduction geometry, revealing clearer separation between offshore slab events and onshore crustal seismicity. This study demonstrates that combining ML‐based detection with established methods provides a scalable and reproducible approach for constructing high‐quality earthquake catalogs in tectonically complex environments and offers practical guidance for adapting similar workflows to other earthquake sequences.

Garcia, Marc [The University of Texas at El Paso, ↗
DOE OSTI2021

Management of the Three Mile Island, Unit 2, Accident Corium and Severely Damaged Fuel Debris

The Three Mile Island, Unit Two (TMI-2) pressurized water reactor core melted down in 1979 due to an untimely combination of maintenance problems that led to a loss of feedwater, followed by a series of operational misunderstandings and errors. The melted core recovery process required development of a wide array of tools. After approximately three years of water management and other cleanup actions, the first views of the core revealed a much higher degree of damage than previously expected. Approximately 62 metric tons of the core had melted, leaving only 42 of the 177 fuel assemblies standing with a majority of rods intact. The core to be recovered was composed of loose debris and a solidified mass of formerly molten fuel. Robotic tools that had been designed for the task were of limited effectiveness due to the range of material types and phases. Over a period of several years, the central melt was broken up, primarily by use of a core-boring drill originally designed to acquire samples through the depth of the debris field. The broken pieces were loaded into specially designed debris canisters by use of long-handled pick-and-place tools and suctioned into baffled knockout canisters using an airlift vacuum system. A remotely operable underwater plasma arc torch was developed for removal of the lower core support structure to be able to retrieve the fuel pieces and secondary melt that had accumulated on the bottom reactor vessel head. Canister design played a central role in defining the initial retrieval process and later affected transportation, interim wet and its current interim dry storage. Due to concerns about the potential for radiolysis of residual water in the debris and other canister material, the canisters were fitted with hydrogen recombiner catalyst units to prevent a buildup of flammable gas and potential pressurization. To confirm the effectiveness of the recombiners during shipping, eight dewatered canisters were kept sealed for up to 205 days with periodic sampling of the headspace gas. The highest hydrogen value (9 vol%) was observed in a canister held for 147 days while the longest stored canister resulted in a 5% hydrogen concentration. The oxygen concentration never exceeded 0.5 %, and the primary backfill was >80% argon, meaning there was no flammability risk. Radiolytic hydrogen was also observed in wet pool storage, where the vented canisters discharged a portion of the water backfill as a result of gas production. The 344 canisters (268 fuel debris, 62 filter, and 12 knockout type) were dewatered, loaded in groups of seven into a double barrier shipping cask, and transported to the U.S. Department of Energy site in Idaho for 10 years of pool storage.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Piezoelectric property of PZT nanofibers characterized by resonant piezo-force microscopy

Nano-piezoelectric materials have drawn tremendous research interest. However, characterization of their piezoelectric properties, especially measuring the piezoelectric strain coefficients, remains a challenge. Normally, researchers use an AFM-based method to directly measure nano-materials’ piezoelectric strain coefficients. But, the extremely small piezoelectric deformation, the influence from the parasitic electrostatic force, and the environmental noise make the measurement results questionable. In this paper, a resonant piezo-force microscopy method was used to accurately measure the piezoelectric deformation from 1D piezoelectric nanofibers. During the experiment, the AFM tip was brought into contact with the piezoelectric sample and set to work at close to its first resonant frequency. A lock-in amplifier was used to pick up the sample’s deformation signal at the testing frequency. By using this technique, the piezoelectric strain constant d 33 of the Lead Zirconate Titanate (PZT) nanofiber with a diameter of 76 nm was measured. The result showed that d 33 of this PZT nanofiber was around 387 pm/V. Meanwhile, by tracking the piezoelectric deformation phase image, domain structures inside PZT nanofibers were identified.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Gravothermal collapse and the diversity of galactic rotation curves

The rotation curves of spiral galaxies exhibit a great diversity that challenges our understanding of galaxy formation and the nature of dark matter. Previous studies showed that in self-interacting dark matter (SIDM) models with a cross section per unit mass of σ/m ≈ $\mathscr{O}$(1) cm 2 /g, the predicted dark matter central densities are a good match to the observed densities in galaxies. Here, in this work, we explore a regime with a larger cross section of σ/m ≈ 20−40 cm 2 /g in dwarf galactic halos. We will show that such strong dark matter self-interactions can further amplify the diversity of halo densities inherited from their assembly history. High concentration halos can enter the gravothermal collapse phase within 10 Gyr, resulting in a high density, while low concentration ones remain in the expansion phase and have a low density. We fit the rotation curves of 14 representative low surface brightness galaxies and demonstrate how the large range of observed central densities is naturally accommodated in the strong SIDM regime of σ/m ≈ 20 – 40 cm 2 /g. Galaxies that are outliers in the previous studies, due to their high halo central densities, are no longer outliers in this SIDM regime as their halos would be in the collapse phase. For galaxies with a low density, the SIDM fits are robust to the variation of the cross section. Our findings open up a new window for testing gravothermal collapse, the unique signature of strong dark matter self-interactions, and exploring a broader SIDM model space. As an example, we illustrate how the larger cross sections favored by our fits, together with upper limits from strong lensing observations in clusters, pick out the preferred SIDM model space for a dark matter particle coupled to a light gauge boson in the Born regime.

dark matter↗
DOE OSTI2024

Statistical and Neural Network for Real Sensor-Data-Driven Anomaly Detection in Nuclear Applications

Anomaly detection (AD) in sensor data is critical to ensure uninterrupted functionality of nuclear power plants (NPPs). Consequently, AD model validation through real-world sensor data is important for applications in nuclear facilities. In this paper, we propose an Autoencoder (AE)—a multi-layered neural network, for AD in sensor data from an operational NPP testbed. Since the dataset lacks labels for irregularities, we introduce random noise and label them to effectively train our model. The proposed AE model assigns a higher reconstruction error to the abnormal samples that deviate from those encountered during the training phase and uses the reconstruction loss to detect anomalies in a representative imbalanced dataset. We also introduce an analytical solution—seasonal trend decomposition (STD)—as another AD scheme for identifying irregularities withinthe same time-series dataset. In contrast to the AE model which relies on reconstruction loss, the STD scheme decomposes the entire dataset into its trend, seasonality, and residual components to pinpoint irregularities. Our findings indicate that the proposed AE and STD models individually achieve recall scores of 97% and 92%, respectively. We validate the performance of the two models on both balanced and imbalanced data. We further solidify the results by picking the combined selected anomalies of the two solutions with an "AND" operator for more reliable predictions.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2024

Statistical and Neural Network for Real Sensor-Data-Driven Anomaly Detection in Nuclear Applications

Anomaly detection (AD) in sensor data is critical to ensure uninterrupted functionality of nuclear power plants (NPPs). Consequently, validation of AD models through real-world sensor data is important for their application in nuclear facilities. In this paper, we propose an Autoencoder (AE)— a multi-layered neural network, for AD in sensor data from an operational NPP testbed. Since the dataset lacks labels for irregularities, we introduce random noise and label them to effectively train our model. The proposed AE model assigns a higher reconstruction error to the abnormal samples that deviate from those encountered during the training phase and uses the reconstruction loss to detect anomalies in a representative imbalanced dataset. We also introduce an analytical solution—seasonal trend decomposition (STD) — as another AD scheme for identifying irregularities within the same time-series dataset. In contrast to the AE model which relies on reconstruction loss, the STD scheme decomposes the entire dataset into its trend, seasonality, and residual components to pinpoint irregularities. Our findings indicate that the proposed AE and STD models individually achieve recall scores of 97% and 92%, respectively. We also validate the performance of the two models on both balanced and imbalanced data. We further solidify the results by picking the combined selected anomalies of the two solutions with an "AND" operator for more reliable predictions.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2021

Phase-weighted slant stacking for surface wave dispersion measurement

SUMMARY Surface wave retrieval from ambient noise records using seismic interferometry techniques has been widely used for multiscale shear wave velocity (Vs) imaging. One key step during Vs imaging is the generation of dispersion spectra and the extraction of a reliable dispersion curve from the retrieved surface waves. However, the sparse array geometry usually affects the ability for high-frequency (>1 Hz) seismic signals’ acquisition. Dispersion measurements are degraded by array response due to sparse sampling and often present smeared dispersion spectra with sidelobe artefacts. Previous studies usually focus on interferograms’ domain (e.g. cross-correlation function) and attempt to enhance coherent signals before dispersion measurement. We propose an alternative technique to explicitly deblur dispersion spectra through use of a phase-weighted slant-stacking algorithm. Numerical examples demonstrate the strength of the proposed technique to attenuate array responses as well as incoherent noise. Three different field examples prove the flexibility and superiority of the proposed technique: the first data set consists of ambient noise records acquired using a nodal seismometer array; the second data set utilizes distributed acoustic sensing (DAS) and a marine fibre-optic cable to acquire a similar ambient noise data set; the last data set is a vibrator-based active-source surface wave data. The enhanced dispersion measurements provide cleaner and higher-resolution spectra without distortions which will assist both human interpreters as well as ML algorithms in efficiently picking curves for subsequent Vs inversion.

58 GEOSCIENCES↗
DOE OSTI2023

Formation and characterization of hydride rim structures in Zircaloy-4 nuclear fuel cladding tubes

Zirconium alloy tubes used as nuclear fuel cladding are subject to oxidation and subsequent hydrogen pickup during their long service in commercial light water reactors. The hydrogen picked up in the cladding can precipitate as a brittle hydride rim feature on the cladding outer surface. Here, to better understand the effect of hydride rims on the fracture behavior of stress-relieved zirconium alloy cladding tubes, a procedure to produce these rim-like structures has been developed and is described herein. Extensive characterization of the ‘as hydrided’ tubes is performed. The hydrogen charging apparatus consists of a tube furnace with a quartz chamber that is connected to a vacuum pump as well as a bottle of pure hydrogen gas. The charging station uses a static charge of hydrogen as opposed to a flowing gas. The chief advantage of this approach is the ability to monitor the pressure drop in the hydriding chamber and correlate this pressure drop to a known rate of hydrogen pickup in the cladding tube. It was found that the hydrogen partial pressure, metal temperature, and surface treatment all clearly played a role in whether a hydride rim was formed. Extensive characterization of the hydride rims shows they consist of needle like platelets of δ phase hydrides (ZrH1.66) oriented in the circumferential direction with a radial spacing of several microns in a sandwich-like structure.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Positron annihilation lifetime spectroscopy study of polyvinylpyrrolidone‐added polyvinylidene fluoride membranes: Investigation of free volume and permeation relationships

ABSTRACT Polyvinylidene fluoride (PVDF) membranes were prepared via the phase inversion method from casting solutions containing PVDF, dimethylformamide (DMF), and polyvinylpyrrolidone (PVP) as pore former. PVP was used in the casting solution in a range of 0–5 wt % and extracted. The effect on membranes of using PVP in the casting process was analyzed by X‐ray diffraction, differential scanning calorimetry, scanning electron microscopy, viscosity, and water permeability techniques. With an increase of PVP from 0 to 5 wt %, the PVDF casting solution viscosities increased from 858 to 1148 cP; the resulting PVDF membrane thickness increased; and the crystallinity of PVDF membranes decreased from 40.0 to 33.3%, which indicates that the addition of PVP inhibits the degree of crystallization in the PVDF membranes. SEM results revealed the shape and size of macropores in the membranes; these macropores changed after PVP addition to the casting solutions. The impact of structural changes on free‐volume properties was evaluated using positron annihilation lifetime spectroscopy (PALS) studies. PALS analysis indicated no effect on the average radius (~3.4 Å) of membrane free‐volume holes from the addition of PVP to the casting solution. However, the percentage of o ‐Ps pick‐off annihilation intensity, I 3 , increased from 1.7 to 5.1% with increased PVP content. Further, increasing the PVP content from 0.5 to 5% resulted in an increased final pure water permeability flux. For instance, the 210 min flux for a 14% PVDF + 0.5% PVP membrane was found to be 3.3 times greater than a control membrane having the same PVDF concentration. © 2020 Wiley Periodicals, Inc. J. Polym. Sci. 2020 , 58 , 589–598

Eren, Bilge↗
DOE OSTI2026

Cryogenic RF characterization of the MAGO cavity for high-frequency gravitational-wave detection

Superconducting radio-frequency (SRF) cavities are promising resonant sensors for gravitational-wave detection in the kHz-MHz frequency range. We report the cryogenic RF characterization of a prototype superconducting niobium cavity with an unconventional geometry designed for narrow electromagnetic mode separation. Following an adapted surface preparation procedure, cryogenic tests were performed at Fermilab and DESY at temperatures down to 2 K. Mechanical tuning at room temperature achieved a mode splitting of approximately 11 kHz at cryogenic temperature. High electromagnetic quality factors consistent with previous prototype cavities were measured. The measurements further revealed phase transfer characteristics relevant for stable low-level RF control as well as indications of mode coupling potentially caused by one-point multipacting. In addition, first cryogenic measurements of the mechanical eigenmodes yielded mechanical quality factors significantly below commonly assumed theoretical values. These results demonstrate the successful application of established SRF preparation and characterization techniques to a non-standard resonator geometry and provide important experimental input for the development of future SRF-based gravitational-wave detectors.

Dokuyucu, Can [DESY]↗
DOE OSTI2021

Development of NDE/NDT Tools for High-Volume & High-Speed Inspection of CFRP Structures in Automotive Manufacturing

Main advantages of the air-coupled ultrasound testing (ACUT) and electromagnetic testing (EMT) techniques for NDE of CFRP composites were non-contact sensing, scalability for high-speed inspection, cost-effectiveness, and non-hazardous operation. Despite these advantages, no systems that would satisfy the project requirements were commercially available. Hence, one of the major efforts of the Michigan State University (MSU) team at the initial stage of the project was to close this technological gap by developing, optimizing, and validating array sensors that would provide sufficient sensitivity, spatial coverage, and resolution for robust defect detection. Optimization of the ACUT and EMT sensor designs was performed using experimentally validated finite element models. Initial experiments using array probes were conducted on relatively flat CFRP samples. In parallel, the MSU team designed and assembled a portable platform with two robotic arms. The robots were equipped with newly designed sensors that enabled high-speed NDE of curved CFRP parts. Presently, the developed robotic platform can be used as a demo/template NDE system, which is easily adaptable to manufacturing environments and in-line NDE. The ACUT NDE system developed by the MSU team used a high-power 4-channel pulser receiver for parallel data acquisition. The array probes were designed by stacking commercially available ACUT transducers, which operated in the frequency range between 100 kHz and 500 kHz. MSU optimized the excitation procedure and developed wave focusing cones so as to reduce the crosstalk between the transducers and to provide higher pulse repletion frequency (PRF). The through-transmission (TT) and single-side access (SSA) inspection modes were successfully implemented. In the TT-ACUT, structural defects in CFRP were detected by passing ultrasonic waves through the test part. Hence, the ACUT transmitters and receivers needed to be placed on the opposite sides of the test part. In the SSA-ACUT, guided waves (GW) were excited in the test part using the transmitters and were sensed by the receivers from the same side. Multi-channel TT-ACUT and SSA-ACUT provided high-speed NDE, and were successfully validated on CFRP test samples with interlaminar delaminations and other embedded defects The EM techniques developed by the MSU team included: 1) eddy current testing (ECT), 2) capacitive imaging (CI) and hybrid dual-mode imaging. In ECT, structural damage was detected in CFRP using coils sensor arrays. In ECT, the excitation magnetic field is generated by passing an alternating current through a coil, which is placed above the test sample. The excitation field penetrates the conductive sample and induces the eddy currents in its transect. In turn, the eddy currents generate the reaction field, which affects the total field sensed by a coil. Hence, the presence of structural flaws will alter the eddy current flow and the picked-up signal. ECT is mostly sensitive to local changes of the electric conductivity of the test sample, and CFRPs are mostly conductive in the direction of carbon fibers. Hence, ECT was well suited for the detection of fiber damage/fiber irregularities. The MSU team developed printed circuit boards (PCB) with coil sensor arrays optimized for NDE of CFRP. Unlike most commercial probes designed for ECT of metallic structures, the MSU array probes were designed for operation in [1-10] MHz frequency range, which was optimal for low-conductive CFRP. Multiple sensing topologies (coil groups excitation/sensing arrangements) were implemented and successfully validated. Capacitive Imaging (CI) technique developed by MSU was complementary to ECT. In contrast to ECT, which was sensitive to local changes of the electrical conductivity, the CI was sensitive to local changes of the dielectric constant. Therefore, CI could provide information about matrix damage/matrix irregularities in CFRP. The MSU CI sensor arrays were made of multiple circular or rectangular open-plate capacitors printed on PCB. Sensors of this type are not commercially available. In addition to ECT and CI, the MSU team developed a hybrid (dual-mode) inductive/capacitive measurement technique that synergistically combined the benefits of inductive and capacitive sensing for rapid NDE of fiber reinforced polymer (FRP) composite structures. Fiber damage and fiber irregularities in FRPs were detected by configuring hybrid sensors as coil sensors. Similarly, matrix damage, matrix irregularities and interlaminar delaminations were detected by configuring hybrid sensors as capacitive sensors. ECT and CI were performed sequentially by means of electronic switching. Hence, eliminating the need for mounting two separate sensor arrays on the probe. Portable robotic platform was developed by MSU for multi-technique high-speed NDE of CFRP test parts. The platform had two 6-axis robots, which enabled inspection of curved parts in approximately a 6×6×6 ft 3 active scan area. On the software side, the MSU team integrated scripts for NDE hardware control with scripts for robot motion control. MSU also implemented automated path planning for the robots, reconstruction of part’s surfaces via stereovision, 3D rendering of inspection data, and image processing algorithms for enhanced defect detection. Automotive composite parts manufactured by Plasan Composites from Phase I were used to validate the ACUT and EMT techniques on representative testbeds. Among those parts were three X-braces for a Dodge Viper, one composite calibration plaque with known defects at known locations, and four other test sections, including sections from a front splitter, a corner section from a composite hood, and a high-pressure RTM panel made using non crimp fabric. Other test samples included CFRP and GFRP calibration plates with fiber/matrix defects fabricated at MSU/CVRC.

36 MATERIALS SCIENCE↗