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DOE OSTI2022

Learning the Temporal Effect in Infrared Thermal Videos With Long Short-Term Memory for Quality Prediction in Resistance Spot Welding

With the advances of sensing technology, in-situ infrared thermal videos can be collected from Resistance Spot Welding (RSW) processes. Each video records the formulation process of a weld nugget. The nugget evolution creates a “temporal effect” across the frames, which can be leveraged for real-time, nondestructive evaluation (NDE) of the weld quality. Currently, quality prediction with imaging data mainly focuses on optical feature extraction with Convolutional Neural Network (CNN) but does not make the most of such temporal effect. In this study, pixels corresponding to critical locations on the weld nugget surface are extracted from a video to form multivariate time series (MTS). Multivariate Adaptive Regression Splines (MARS) is used in MTS processing to remove noisy signals related to uninformative frames. A Stacked Long Short-Term Memory (LSTM) model is developed to learn from the processed MTS and then predicts weld nugget size and thickness in real-time NDE. Results from a case study on RSW of Boron steel demonstrates the improvement in prediction accuracy and computational time with the proposed method, as compared to CNN-based weld quality prediction.

Guo, Shenghan↗

DOE OSTI2025

Deep Point Cloud Building Envelope Segmentation (DeeP-CuBES) using Deep Learning

Building Information Modeling (BIM) plays an important role in building design and construction, particularly for achieving energy-efficient retrofits. Building envelope retrofits using panelized prefabricated system, such as those popularized by the Energiesprong program, need accurate as-built dimensions of facade features (windows, doors, etc.) to achieve the desired thermal and air tightness. Traditionally, building surveying is done manually, resulting in a time-consuming and labor-intensive process. Recently, 3D point clouds from terrestrial LiDAR have been used to automate the generation of as-built dimensions of existing buildings. However, automated BIM using LiDAR relies on solving the point cloud semantic segmentation (PCSS) problem. In this work, we propose a robust pipeline for solving the PCSS problem using deep neural networks, focusing on overcoming challenges posed by imbalanced datasets and complex architectural features. We introduce the first high-density, labeled, and validated building envelope point cloud dataset derived from multiple building scans, specifically curated to tackle challenges in facade-level segmentation. Results from the trained neural networks show that advanced attention-based architectures and incorporating radiometry (light intensity and RGB) features significantly boost segmentation accuracy for windows and doors.

Selvakumar, Balaji [ORNL]↗

NASA NTRS1992

The crystallization and crystalline properties of LARC-TPI

LARC-TPI, a thermoplastic polyimide, has been studied in order to develop an understanding of its crystalline phase transition. Our experiments suggest that samples synthesized in different laboratories apparently had different degrees of imidization and their thermal behaviors differed accordingly. When the most crystalline of these polyimides was studied in some detail, we found that it melted irreversibly in that once a sample was completely melted it would not recrystallize. A polymer that did not recrystallize displayed a glass transition, which increased in temperature upon subsequent cooling and reheating. Solubility experiments indicated that heating above the crystalline melting temperature led to network formation in the polymer, a conclusion that is consistent with other behavior just mentioned. Differential calorimetric studies revealed that annealing at slow heating rates or under isothermal conditions resulted in dual melting transitions. These studies, supported by X-ray diffraction results, strongly indicate that the annealing process involves a solid-liquid-solid transformation. From an existing phenomenological model for the kinetics of phase transitions, kinetic parameters for these crystallizations have been evaluated. The Avrami exponents n increased with the annealing temperature in the protocol used in this study. Their values were about 2 or lower, thus indicating that crystallization may have followed a mechanism that included heterogeneous nucleation of a low dimensional order in which all the embryonic crystallites formed at the beginning of the process. A positive temperature coefficient for these crystallizations indicated that diffusion may have had a rate controlling influence and affected the values of n.

Theil, Michael H.↗

DOE OSTI2022

A Case Study of the Weather Research and Forecasting Model Applied to the Joint Urban 2003 Tracer Field Experiment. Part III: Boundary-Layer Parametrizations

Numerical weather prediction is often used to supply the mean wind and turbulence fields for atmospheric transport and dispersion plume models as they provide dense geographic coverage in comparison to typically sparse monitoring networks. Here, the Weather Research and Forecasting (WRF) model 4.0 was run over the month-long period of the Joint Urban 2003 field campaign conducted in Oklahoma City. We compare three different simulations in their ability to reproduce the observations, each using a different boundary-layer parametrization. Specifically, we examine the Mellor–Yamada–Janjic (MYJ), Yonsei University (YSU), and Mellor–Yamada–Nakanishi–Niino (MYNN) boundary-layer parametrizations. All three predict the wind speed well during the day but overpredict it at night. The MYNN parametrization is better than MYJ at predicting the daytime turbulence in the surface layer, but both underpredict the nocturnal turbulence. Additionally, the MYJ parametrization is best at predicting the reciprocal Obukhov length, while MYNN and YSU both significantly overpredict thermal stability. Reconstructing the reciprocal Obukhov length from other simulated parameters produces more accurate values for both parametrizations. All three models overpredict the boundary-layer height, particularly under convective conditions. The MYJ parametrization overestimates boundary-layer height the most, while YSU and MYNN have comparable performance with MYNN having an advantage in predicting the stable boundary-layer height. Several days were found where the WRF simulations predict significant deviations from the prevailing diurnal pattern in wind direction, which are not found in the observations.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2020

Quantification of Dispersion for Weakly and Strongly Correlated Nanofillers in Polymer Nanocomposites

The dispersion of nanoparticles in viscous polymers is dictated by kinetics, interaction potentials between particles, and interfacial compatibility between the matrix and dispersed phases. It was previously proposed that an analogy can be made between thermally dispersed colloids and kinetically dispersed nanoparticles in viscous media when weak interactions exist between particles allowing for a mean-field description under the Ginzburg criterion such as for carbon black dispersed in polybutadiene elastomer. For these cases, the second virial coefficient can be used to quantify the quality of dispersion; additionally, the nanoscale network mesh size can be calculated, which is related to dynamic properties. However, this approach fails for nanoparticles with surface charges or other specific interactions that lead to correlations. Here, these correlated systems are investigated in the context of the mean-field systems in order to gain a comparative description of dispersion using the network mesh size and a derived virial coefficient. The physical origin of the structural parameters from the proposed model for these correlated systems is investigated.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2019

Experimental and Computational Analysis of NEAMS Pebble Bed Reactors

The Advanced High-Temperature Pebble Bed Reactor concept leverages a particle-based fuel format consisting of discrete spherical graphite pebbles arrayed in a packed bed architecture. Thermal regulation achieved via flow of gas (e.g., helium) or liquid (e.g., molten salt) coolants through the void spaces between pebbles in the bed (characteristic pebble diameters: ~ 6 cm, gas cooled; ~ 3 cm, liquid cooled). This design is of interest owing to inherent advantages including passive safety features and highly efficient heat transfer characteristics that enable high power densities to be achieved. Fully leveraging these advantages requires a fundamental understanding of the complex coolant flow structure within the pebble-shaped fuel bed. Unfortunately, complexities associated with non-invasively probing the micro-scale flow phenomena within the complex network of void spaces between pebbles have hindered efforts to characterize the underlying transport phenomena. Without this fundamental foundation, it becomes challenging to rationally construct macroscopic transport models based upon volume averages of micro-scale parameters that accurately capture the observed flow behavior. Consequently, this lack of fundamental knowledge has limited previous work to coarse comparisons between theory and extremely limited experimental data. Moreover, these comparisons have been made only in terms of integral or macroscopic results. Therefore, multipoint measurements with a high level of spatial and temporal resolution are critically needed to fully map the complex flow patterns and to provide data at high spatial density to permit accurate volume averaging in the pebble bed. For this project, we performed a coordinated experimental and computational effort to quantitatively map the full-field velocity and temperature fields in the interstitial spaces within the pebble bed. The major accomplishments of this project included the important knowledge acquired for the flow mixing and heat transfer in the interstitial pore scales, the effects of flow mixing in the near-wall and far-wall regions, and the by-pass flows of pebble bed systems. The produced high-resolution experimental data (not broadly available in existing literature) were then used for the numerical studies enabling the refinement and validation of standard simulation tools (Nek5000).

42 ENGINEERING↗

DOE OSTI2021

A semi-analytical model for laser induced densification in fused silica at elevated temperatures

A semi-analytical model for deterministic surface smoothing of fused silica below the evaporation temperature threshold is presented. Using this model, a method for calculating deterministic track depths for laser polishing fused silica is derived and validated with experiments. In this work, model predictions were in good agreement with experiment across varying laser preheating temperature and power. With the semi-analytical method presented here, deterministic laser smoothing can be achieved in the densification regime to close the process loop of laser polishing.

36 MATERIALS SCIENCE↗

DOE OSTI2025

The value of integrating a geothermal district heating system into a microgrid

As electrical grids increasingly rely on variable renewable energy, maintaining reliability and cost efficiency becomes more complex. To address these challenges, this study analyzed the integration of geothermal district heating as a grid-responsive thermal resource within a microgrid in Tuttle, Oklahoma. Building energy modeling using EnergyPlus estimated annual district heating demand at 2.9 GWh, with a peak load of 2.8 MW th . Techno-economic analyses were conducted to meet the heating demand under three geothermal scenarios, varying by production depth, flow rate, and thermal output, each supplemented by natural gas peaking boilers. In parallel, equivalent electrical load profiles were developed using typical coefficients of performance (COPs) for air-source heat pumps and electric boilers to establish an electrified baseline scenario. A complete end-use electrical load profile was also developed for the microgrid using Cambium dataset. The modeling results demonstrated reliable and economic operation of the geothermal systems over 30 years, with COPs ranging from 2.6 to 8.9 and the lowest levelized heating cost at $\$$54.6/MWh. Geothermal integration reduced electricity consumption by up to 94.7 % compared to the non-geothermal base case, yielding annual energy savings of up to $\$$803 k. Avoided grid costs ranged from $\$$65 k–$\$$147 k per year, with individual events avoiding up to $\$$4,863 per hour. Grid-responsive operation further reduced wholesale energy costs by 53–56 %. These findings demonstrate geothermal heating, traditionally treated as a non-grid-responsive thermal resource, can be reconfigured to support dynamic grid services, offering a scalable pathway to enhance reliability and reduce costs in renewable-rich microgrids and district heating networks.

15 GEOTHERMAL ENERGY↗

DOE OSTI2023

Utah FORGE 5-2565: Hydrothermal Evolution of Fracture Properties - Workshop Presentation

This is a presentation on the Evolution of Permeability and Strength Recovery of Shear Fractures Under Hydrothermal Conditions project by the U.S. Geological Survey, presented by Dr. David Lockner. The project's objective was to determine how thermal, hydraulic, mechanical, and chemical processes affect the sustainability of fracture networks in geothermal reservoirs and provide strategies for improved EGS techniques that maximize thermal coupling and increase reservoir longevity. This presentation was featured in the Utah FORGE R&D Annual Workshop on September 8, 2023. The workshop provided a valuable opportunity to explore the progress made in each of the 17 Research and Development projects funded under Solicitation 2020-1 which aim to enhance our understanding of the crucial factors influencing the development of Enhanced Geothermal Systems (EGS) reservoirs and resources.

15 GEOTHERMAL ENERGY↗

DOE OSTI2021

Ag-doped As–S–Se chalcogenide glasses: a correlative study of structural and dielectrical properties

This work is focused on investigating the effect of Ag doping on the dielectric and structural properties of the As–S–Se glass system and their suitability for potential applications in optoelectronics, such as electronic and switching components. A series of glasses from the system Agx(As40S30Se30)100-x (x = 5 at.% Ag) were prepared with melt-quenching technique. Morphological and compositional analysis was performed by scanning electron microscopy and energy-dispersive X-ray spectroscopy. Raman spectroscopy measurements have shown structural modifications of the glass network upon Ag doping, with creation of new Ag–(S,Se)–As structures, resulting in increased number of defect states. Variations in dielectric permittivity (e') and dielectric loss (e") were investigated in a wide frequency and temperature range, and explained by dominant dipolar and electronic polarization, as well as correlated with the observed structural changes. Improvement in dielectric properties is observed upon doping with Ag. Furthermore, the low dielectric tangent loss at high frequencies for all glassy samples points to a beneficial ability of the material to absorb energy of the external electric field. Good thermal stability of these glasses is confirmed by the calculated temperature coefficient of the dielectric permittivity. Density of localized states in all glasses was determined from AC conductivity and the dielectric tangent loss using a correlated barrier hopping model, and found to increase with Ag concentration. The overall results suggest that Ag doping enhances the electrical and optical quality of this type of glasses, making them suitable as nonlinear optical materials and their applications in devices.

36 MATERIALS SCIENCE↗

NASA NTRS1993

AIAA/ASME/ASCE/AHS/ASC Structures, Structural Dynamics, and Materials Conference, 34th and AIAA/ASME Adaptive Structures Forum, La Jolla, CA, Apr. 19-22, 1993, Technical Papers. Pts. 1-6

Topics addressed include the prediction of helicopter component loads using neural networks, spacecraft on-orbit coupled loads analysis, hypersonic flutter of a curved shallow panel with aerodynamic heating, thermal-acoustic fatigue of ceramic matrix composite materials, transition elements based on transfinite interpolation, damage progression in stiffened composite panels, a direct treatment of min-max dynamic response optimization problems, and sources of helicopter rotor hub inplane shears. Also discussed are dynamics of a layered elastic system, confidence bounds on structural reliability, mixed triangular space-time finite elements, advanced transparency development for USAF aircraft, a low-velocity impact on a graphite/PEEK, an automated mode-tracking strategy, transonic flutter suppression by a passive flap, a nonlinear response of composite panels to random excitation, an optimal placement of elastic supports on a simply supported plate, a probabilistic assessment of composite structures, a model for mode I failure of laminated composites, a residual flexibility approach to multibody dynamics,and multilayer piezoelectric actuators.

Source record↗

NASA NTRS1997

Visual Computing Environment

The Visual Computing Environment (VCE) is a NASA Lewis Research Center project to develop a framework for intercomponent and multidisciplinary computational simulations. Many current engineering analysis codes simulate various aspects of aircraft engine operation. For example, existing computational fluid dynamics (CFD) codes can model the airflow through individual engine components such as the inlet, compressor, combustor, turbine, or nozzle. Currently, these codes are run in isolation, making intercomponent and complete system simulations very difficult to perform. In addition, management and utilization of these engineering codes for coupled component simulations is a complex, laborious task, requiring substantial experience and effort. To facilitate multicomponent aircraft engine analysis, the CFD Research Corporation (CFDRC) is developing the VCE system. This system, which is part of NASA's Numerical Propulsion Simulation System (NPSS) program, can couple various engineering disciplines, such as CFD, structural analysis, and thermal analysis. The objectives of VCE are to (1) develop a visual computing environment for controlling the execution of individual simulation codes that are running in parallel and are distributed on heterogeneous host machines in a networked environment, (2) develop numerical coupling algorithms for interchanging boundary conditions between codes with arbitrary grid matching and different levels of dimensionality, (3) provide a graphical interface for simulation setup and control, and (4) provide tools for online visualization and plotting. VCE was designed to provide a distributed, object-oriented environment. Mechanisms are provided for creating and manipulating objects, such as grids, boundary conditions, and solution data. This environment includes parallel virtual machine (PVM) for distributed processing. Users can interactively select and couple any set of codes that have been modified to run in a parallel distributed fashion on a cluster of heterogeneous workstations. A scripting facility allows users to dictate the sequence of events that make up the particular simulation.

Lawrence, Charles↗

NASA NTRS2021

Cincinnati & Covington Urban Development II: Assessing Flooding and Landslide Susceptibility Along the Ohio-Kentucky Border

Landslides and flooding are reoccurring environmental hazards that lead to health risks and economic burdens in the urban areas of Cincinnati, Ohio and Covington, Kentucky. These communities share underlying natural and artificial conditions that make them vulnerable to these hazards, including excessive precipitation, weak lithology, high impervious surface levels, and steep slopes. Despite the human and economic risks associated with these environmental hazards, the areas of highest vulnerability within the region remain unknown. NASA DEVELOP partnered with Groundwork USA and Groundwork Ohio River Valley (ORV) to assess the region’s susceptibility to landslides and flooding. The team utilized NASA Earth observations, including the Landsat 8 Operational Land Imager (OLI), Landsat 8 Thermal Infrared Sensor (TIRS), and Global Precipitation Measurement (GPM) Integrated Multi-satellitE Retrieval for GPM (IMERG), alongside ancillary datasets to map landslide susceptibility and exposure throughout the study area. The team also used ancillary data to map surface runoff and runoff retention using the Natural Capital Project’s Integrated Valuation of Ecosystem Services and Tradeoffs (InVEST) Urban Flood Risk Mitigation Model. The resulting landslide susceptibility and exposure maps highlight the neighborhoods around Avondale and Fairmount as areas of particularly high landslide exposure. Meanwhile, the InVEST outputs demonstrate that Downtown Cincinnati and the Queensgate neighborhood retain the least amount of rainfall. This research provides partners with a more complete hazard analysis of the greater Cincinnati area while also producing refined methodologies to enhance future flood and landslide vulnerability mapping throughout Groundwork USA’s nationwide network of communities.

Paxton LaJoie↗

NASA NTRS1997

CO and the Temperature Structure of the Solar Atmosphere

The surface layers of the Sun provide a crucial boundary condition for many of the processes that occur in the deep interior. The stratification of the outer solar atmosphere once was thought to be well understood. However, studies of thermally sensitive molecular absorptions in the infrared revealed puzzling anomalies. Strong lines of the CO fundamental vibration-rotation bands near 5 microns showed very cool temperatures at the extreme limb, and remarkable off-limb emissions extending well into the supposedly hot chromosphere. The conflicting pictures of the photosphere/chromosphere interface, from the widely separated wavelength regimes, has raised suspicions that those "layers" of the atmosphere are much more inhomogeneous than previously suspected. One proposal is that the low chromosphere is dominated by cool gas--the "COmosphere," if you will--which is threaded by a network of persistent small-scale hot magnetic filaments and occasionally disrupted by localized acoustic disturbances. The COmosphere is capped by the merged fields of the network elements in the chromospheric "canopy." I will describe the evidence in favor of that model, including recent work at the NSO McMath-Pierce telescope (including use of the new "Phoenix" spectrometer) and translimb far-UV spectroscopy by SOHO/SUMER.

Ayres, Thomas R.↗

DOE OSTI2023

Scalable manufacturing of quantum light emitters in silicon under rapid thermal annealing

Quantum light sources play a fundamental role in quantum technologies ranging from quantum networking to quantum sensing and computation. The development of these technologies requires scalable platforms, and the recent discovery of quantum light sources in silicon represents an exciting and promising prospect for scalability. The usual process for creating color centers in silicon involves carbon implantation into silicon, followed by rapid thermal annealing. However, the dependence of critical optical properties, such as the inhomogeneous broadening, the density, and the signal-to-background ratio, on centers implantation steps is poorly understood. We investigate the role of rapid thermal annealing on the dynamic of the formation of single color centers in silicon. We find that the density and the inhomogeneous broadening greatly depend on the annealing time. We attribute the observations to nanoscale thermal processes occurring around single centers and leading to local strain fluctuations. Our experimental observation is supported by theoretical modeling based on first principles calculations. The results indicate that annealing is currently the main step limiting the scalable manufacturing of color centers in silicon.

42 ENGINEERING↗

DOE OSTI2024

HELIOCOMM: Wireless Controls State-of-the-Art Report

This report introduces the concept of wireless controls in heliostat-based concentrating solar thermal power (CSP) systems. Specifically, the need for wireless communications to be implemented within the heliostat-based CSP systems is identified versus the existing approaches that follow wireline connections which suffer from high installation, operation, and maintenance cost. Furthermore, this report analyzes the most recent advances in the field of developing wireless controls in heliostat-based CSP systems, which are highlighted to be in their infancy given the primitive wireless networking solutions that they currently utilize and test. The main contribution of this report is the introduction of a novel HELIOCOMM system that supports the wireless controls in heliostat-based CSP systems by exploiting the next generation networking technology of integrated access and backhaul. Furthermore, the proposed HELIOCOMM system performs an artificial intelligent clustering approach of the heliostats and clusterhead selection and develops an entropy-based routing model to enable the heliostats to communicate with the central station by considering their energy availability and network traffic. Also, towards efficiently exploiting the limited resources in the developed wireless communication system, a resource allocation module is introduced that performs the maximization of the energy efficiency of each heliostat by minimizing its corresponding experienced end-to-end latency to communicate with the central station, while performing an intelligent bandwidth splitting in the access and backhaul wireless links. The overall architecture is presented, and its individual building components are discussed in detail.

14 SOLAR ENERGY↗

NASA NTRS2006

Studies of acoustic-electric feed-throughs for power transmission through structures

There are numerous engineering design problems where the use of wires to transfer power and communicate data thru the walls of a structure is prohibitive or significantly difficult that it may require a complex design. Using physical feedthroughs in such systems may make them susceptible to leakage of chemicals or gasses, loss of pressure or vacuum, as well as difficulties in providing adequate thermal or electrical insulation. Moreover, feeding wires thru a wall of a structure reduces the strength of the structure and makes the structure prone to cracking due to fatigue that can result from cyclic loading and stress concentrations. One area that has already been identified to require a wireless alternative to electrical feedthroughs is the container of the Mars Sample Return Mission, which will need wireless sensors to sense a pressure leak and to avoid potential contamination. The idea of using elastic or acoustic waves to transfer power was suggested recently by [Y. Hu, et al., July 2003]. This system allows for the avoidance of cabling or wiring. The technology is applicable to the transfer of power for actuation, sensing and other tasks inside any sealed container or vacuum/pressure vessel. An alternative approach to the modeling presented previously [Sherrit et a., 2005] used network analysis to solve the same problem in a clear and expandable manner. Experimental tests on three different designs of these devices were performed. The three designs used different methods of coupling the piezoelectric element to the wall. In the first test the piezoelectric material was bolted using a backing structure. In the second test the piezoelectric was clamped after the application of grease and finally the piezoelectric element was attached using a conductive epoxy. The mechanical clamp with grease produced the highest measured efficiency of 53% however this design was the least practical from a fabrication viewpoint. The power transfer efficiency of conductive epoxy joint was 40% and the stress bolts (12%).

ultrasonics↗

NASA NTRS1978

Laserfax

The photo shows an Associated Press technician receiving a photograph prepared by means of a high speed, high resolution facsimile system known as Laserfax, so called because it employs a laser beam to scan the photo being sent. Laser scanning data is converted to electrical signals and transmitted to news bureaus within the Associated Press network via microwave radio or telephone lines. At the other end, another laser sweeps reconverted imagery onto a special, light-sensitive, dry silver paper. The paper is then heat processed to reproduce the photograph. Manufactured by Harris Electronics Systems Inc., Melbourne, Florida, Laserfax incorporates NASA thermal control coating technology developed by Jet Propulsion Laboratory for use on spacecraft antennas; the coatings block absorption of solar radiation which would interfere with the antenna's proper operation. Harris Electronics Systems, originally Radiation, Inc., reused the NASA technology in development of Laserfax. A NASA technical support package provided information about the thermal properties that could be expected of various coatings for the facsimile system's paper rollers; this information served as a design base for the infrared heat source used in developing the photo. Although relatively new, Laserfax is in extensive service. It is manufactured in several models. One of them is the type used by the Associated Press, its news bureaus and affiliated newspapers, radio and television stations. Other models have been sold in large numbers to law enforcement agencies for transmitting high quality fingerprints and identification photos. Laserfax is also in service with the National Weather Service, which converts satellite imagery to weather photographs and relays them to local weather stations, television stations, newspapers and airlines.

Source record↗