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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Transformer Health Monitoring Using Dissolved Gas Analysis

As integral components of any power plant, transformers supply the generated electricity to the grid. However, a transformer’s cellulose-based paper insulation and the mineral oil in which it is immersed break down over time under standard operating conditions—or more rapidly due to potential faults within the system. As the transformer’s mineral oil breaks down, gases are released that can be measured and monitored. This technical brief exhibits a collection of diagnostic and prognostic techniques that utilities can adopt in lieu of labor-intensive periodic preventive maintenance routines. Furthermore, prognostic models have been incorporated using the latest version of the Institute of Electrical and Electronics Engineers (IEEE) standard (IEEE, 2019) for dissolved gas analysis (DGA), thus expanding it to include estimation of the time to maintenance. Overall, four different methodologies are explained, each of which aids in determining a transformer’s state of health. These methodologies include the Chendong model, the IEEE thermal life consumption model (IEEE, 2012), a diagnostic model for DGA, and a prognostic model for DGA that uses an autoregressive integrated moving average (ARIMA) model. An additional improvement for estimating missing system parameters by using monitoring data (i.e., a tool for parameter estimation utilizing Powell’s method) is presented, enabling the IEEE thermal life consumption model to benefit not only the collaborating power plant, but also the power industry at large.

24 POWER TRANSMISSION AND DISTRIBUTION↗
NASA NTRS2010

A Microwave Blade Tip Clearance Sensor for Propulsion Health Monitoring

Microwave sensor technology is being investigated by the NASA Glenn Research Center as a means of making non-contact structural health measurements in the hot sections of gas turbine engines. This type of sensor technology is beneficial in that it is accurate, it has the ability to operate at extremely high temperatures, and is unaffected by contaminants that are present in turbine engines. It is specifically being targeted for use in the High Pressure Turbine (HPT) and High Pressure Compressor (HPC) sections to monitor the structural health of the rotating components. It is intended to use blade tip clearance to monitor blade growth and wear and blade tip timing to monitor blade vibration and deflection. The use of microwave sensors for this application is an emerging concept. Techniques on their use and calibration needed to be developed. As a means of better understanding the issues associated with the microwave sensors, a series of experiments have been conducted to evaluate their performance for aero engine applications. This paper presents the results of these experiments.

Woike, Mark R.↗
NASA NTRS1984

Reusable rocket engine turbopump condition monitoring

Significant improvements in engine readiness with reductions in maintenance costs and turn-around times can be achieved with an engine condition monitoring systems (CMS). The CMS provides health status of critical engine components, without disassembly, through monitoring with advanced sensors. Engine failure reports over 35 years were categorized into 20 different modes of failure. Rotor bearings and turbine blades were determined to be the most critical in limiting turbopump life. Measurement technologies were matched to each of the failure modes identified. Three were selected to monitor the rotor bearings and turbine blades: the isotope wear detector and fiberoptic deflectometer (bearings), and the fiberoptic pyrometer (blades). Signal processing algorithms were evaluated for their ability to provide useful health data to maintenance personnel. Design modifications to the Space Shuttle Main Engine (SSME) high pressure turbopumps were developed to incorporate the sensors. Laboratory test fixtures have been designed for monitoring the rotor bearings and turbine blades in simulated turbopump operating conditions.

Hampson, M. E.↗
NASA NTRS1985

Reusable rocket engine turbopump condition monitoring

Significant improvements in engine readiness with attendant reductions in maintenance costs and turnaround times can be achieved with an engine condition monitoring system (CMS). The CMS provides real time health status of critical engine components, without disassembly, through component monitoring with advanced sensor technologies. Three technologies were selected to monitor the rotor bearings and turbine blades: the isotope wear detector and fiber optic deflectometer (bearings), and the fiber optic pyrometer (blades). Signal processing algorithms were evaluated and ranked for their utility in providing useful component health data to unskilled maintenance personnel. Design modifications to current configuration Space Shuttle Main Engine (SSME) high pressure turbopumps and the MK48-F turbopump were developed to incorporate the sensors.

Hampson, M. E.↗
NASA NTRS2013

Validation of Helicopter Gear Condition Indicators Using Seeded Fault Tests

A "seeded fault test" in support of a rotorcraft condition based maintenance program (CBM), is an experiment in which a component is tested with a known fault while health monitoring data is collected. These tests are performed at operating conditions comparable to operating conditions the component would be exposed to while installed on the aircraft. Performance of seeded fault tests is one method used to provide evidence that a Health Usage Monitoring System (HUMS) can replace current maintenance practices required for aircraft airworthiness. Actual in-service experience of the HUMS detecting a component fault is another validation method. This paper will discuss a hybrid validation approach that combines in service-data with seeded fault tests. For this approach, existing in-service HUMS flight data from a naturally occurring component fault will be used to define a component seeded fault test. An example, using spiral bevel gears as the targeted component, will be presented. Since the U.S. Army has begun to develop standards for using seeded fault tests for HUMS validation, the hybrid approach will be mapped to the steps defined within their Aeronautical Design Standard Handbook for CBM. This paper will step through their defined processes, and identify additional steps that may be required when using component test rig fault tests to demonstrate helicopter CI performance. The discussion within this paper will provide the reader with a better appreciation for the challenges faced when defining a seeded fault test for HUMS validation.

Dempsey, Paula↗
NASA NTRS2019

Model-based System Health Management and Contingency Planning for Autonomous UAS

Safe autonomous operations of an Unmanned Aerial System (UAS) requires that the UAS can react to unforeseen circumstances, for example, after a failure has occurred. In this paper we describe a model-based run-time architecture for autonomous on-board diagnosis, system health management, and contingency management. This architecture is being instantiated on top of NASA's Core Flight System (cFS/cFE) as amajor component of the on-board AutonomousOperating System (AOS). We will describe our diagnosis and monitoring components, which continuously provide system health status. Automated reasoning with constraint satisfaction form the core of our decision-making component, which assesses the current situation, aids in failure disambiguation, and constructs a contingency plan to mitigate the failure(s) and allow for a safe end of the mission. We will illustrate our contingency management system with two case studies, one for a fixed-wing aircraft in simulation, and one for an autonomous DJI S1000+ octo-copter.

Schumann, Johann M.↗
DOE OSTI2022

Functional fiber-optic sensors embedded in stainless steel components using ultrasonic additive manufacturing for distributed temperature and strain measurements

The nuclear industry is progressing toward microreactors that can be factory assembled and deployed to remote regions for reliable, scalable power generation. However, the reduced power output requires enhanced monitoring capabilities to reduce staffing and eventually move toward autonomous control to improve the economics of microreactors. The ability to embed sensors such as fiber-optics, which can provide spatially distributed temperature and strain measurements, within microreactor components for real-time health monitoring would be particularly advantageous. Recent advances in ultrasonic additive manufacturing (UAM) have demonstrated the successful embedding of fiber-optics in soft materials such as Al and Cu by placing the sensors in machined cavities and ultrasonically welding over the top with thin foils. This article reports the first successful embedment of fiber-optic sensors and thermocouples within a common nuclear reactor material, SS304, via UAM. UAM parameters were first explored with simple plate geometries before moving to more complex geometries, such as pipes and other test articles for heat pipe–based microreactors. Select samples were sectioned for microscopy to evaluate the sensor/foil and foil/foil interfaces from samples fabricated by using 100% SS304 foils vs. foils plated with a Ni coating to improve UAM bonding. Furthermore, embedding metal-coated, low-bend loss fibers resulted in greatly reduced signal attenuation and adequate compressive residual strain in the embedded region to ensure successful strain coupling. Pipe specimen functional testing was performed by monitoring temperature and strain during transient and steady-state thermal testing.

36 MATERIALS SCIENCE↗
NASA NTRS2004

Concept for Inclusion of Analytical and Computational Capability in Optical Plume Anomaly Detection (OPAD) for Measurement of Neutron Flux

Researchers are working on many fronts to make possible high-speed, automated classification and quantification of constituent materials in numerous environments. NASA's Marshall Space Flight Center has implemented a system for rocket engine flowfields/plumes. The Optical Plume Anomaly Detector (OPAD) system was designed to utilize emission and absorption spectroscopy for monitoring molecular and atomic particulates in gas plasma. An accompanying suite of tools and analytical package designed to utilize information collected by OPAD is known as the Engine Diagnostic Filtering System (EDiFiS). The current combination of these systems identifies atomic and molecular species and quantifies mass loss rates in H2/O2 rocket plumes. Capabilities for real-time processing are being advanced on several fronts, including an effort to hardware encode components of the EDiFiS for health monitoring and management. This paper addresses the OPAD with its tool suites, and discusses what is considered a natural progression: a concept for taking OPAD to the next logical level of high energy physics, incorporating fermion and boson particle analyses in measurement of neutron flux.

Patrick, Marshall Clint↗
NASA NTRS2018

New Sensors and Techniques for Aircraft Engine Health Monitoring

The ability to monitor the health of the rotating components in aircraft engines is of major interest to aero community in improving safety and reliability. The use of instrumentation for these applications remains very challenging. It requires sensors and techniques that are highly accurate, able to operate in a high temperature environment, and sensitive enough to detect minute changes and hidden flaws before undesired events occur. The National Aeronautics and Space Administration (NASA), through several Aviation Safety Programs, has taken a leadership role in the development of new sensor technologies and techniques for the in-situ health monitoring of aircraft turbine engines. Along with the development of new instrumentation for aircraft engines, the Glenn Research Center has a diverse set of ground test facilities that are used to simulate the conditions that a vehicle would see in flight allowing new concepts to be safely developed and evaluated on the ground before progressing to actual flight. In this presentation Mark will give an overview of the NASA Glenn Research Center, discuss its past aviation safety initiatives, present some select sensors that have been developed for aircraft engine safety, and then conclude with some new measurement techniques that have been developed for use at the NASA Glenn test facilities, enabling better measurement and simulation of flight conditions. He will discuss current research and development efforts that he is working on at the NASA Glenn Research Center in the areas of new sensors and techniques for aircraft engine health monitoring. This work is being conducted in support of aviation safety.

Turbine↗
DOE OSTI2021

Structural Health Monitoring of Microreactor Safety Systems Using Convolutional Neural Networks

Microreactors, a class of modular reactors with net power output of less than 20 MWth, have innovative applications in nuclear and nonnuclear industries due to their portability, reliability, resilience, and high capacity factors. In order to operate microreactors on a wider scale, it is essential to bring down maintenance life-cycle costs while ensuring the integrity of operating such systems. Autonomous operations in microreactors using augmented digital-twin (DT) technology can serve as a cost-effective solution by increasing awareness about the system’s health. Structural health monitoring (SHM) is a key component of nuclear DT frameworks. Artificial neural networks can be beneficial to detect degradation in the nuclear safety systems, such as piping equipment systems, by monitoring the sensor data obtained from the plant and its corresponding structures, systems and components. In this report, an SHM methodology is presented which uses convolutional neural networks to determine degraded locations and their corresponding degradation-severity levels at various locations of nuclear piping equipment systems. A simple pipe system, subjected to seismic loads, is selected to design the post-hazard SHM framework. The effectiveness of the proposed SHM methodology is demonstrated by obtaining high accuracy in detecting degraded locations as well as the severity levels.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
NASA NTRS2008

Overview of the Smart Network Element Architecture and Recent Innovations

In industrial environments, system operators rely on the availability and accuracy of sensors to monitor processes and detect failures of components and/or processes. The sensors must be networked in such a way that their data is reported to a central human interface, where operators are tasked with making real-time decisions based on the state of the sensors and the components that are being monitored. Incorporating health management functions at this central location aids the operator by automating the decision-making process to suggest, and sometimes perform, the action required by current operating conditions. Integrated Systems Health Management (ISHM) aims to incorporate data from many sources, including real-time and historical data and user input, and extract information and knowledge from that data to diagnose failures and predict future failures of the system. By distributing health management processing to lower levels of the architecture, there is less bandwidth required for ISHM, enhanced data fusion, make systems and processes more robust, and improved resolution for the detection and isolation of failures in a system, subsystem, component, or process. The Smart Network Element (SNE) has been developed at NASA Kennedy Space Center to perform intelligent functions at sensors and actuators' level in support of ISHM.

Perotti, Jose M.↗
DOE OSTI2022

Strain Gauge Diagnostic Development for use in Vessel Health Monitoring for Hydro-shots

Six-foot vessels are a crucial component to protecting high fidelity equipment at DARHT. Analysis shows these vessels have a limited life span (~10 shots) due to fatigue, ratcheting, and damage accumulation. Vessel health monitoring and diagnostics can help inform decision on a vessel’s fitness for service. Strain gauges are an easy and effective sensor for use in vessel health monitoring. In early March, J-2 executed a qualification shot, uniform blast loading with minimal fragments, with bi-axial strain gauges fielded at four locations around vessel. Several damage features were extracted from the data, and frequency content helps to validate computer modelling of the vessel response. Permanent plastic strain at each location was significant with location one having the most strain at the end state, with 230 micro-strain. However, residual pressure in the vessel could be a major factor in this strain. PEEQ is a measure of total plastic equivalent strain accumulation. The equivalent strain at location one exceeded the plastic strain limit four times and accumulated the most PEEQ with 2036 micro-strain. As expected, this qualification shot did contribute to damage in the vessel, and should be considered in its fitness for service, but not critical enough to pull it from service. Frequency content also gave valuable information on the modal response of the vessel and contributes to the understanding of how the vessel responds to the initial blast load with an expected lower frequency membrane/breathing mode and transitioning to higher frequency bending modes in the vessel wall.

42 ENGINEERING↗
DOE OSTI2023

Advanced Monitoring and Control in the ANL METL Facility Using an Engineering Digital Twin

The potential benefits of using an engineering digital twin to achieve greater autonomy for monitoring and control functions in advanced reactors was investigated for the Mechanisms Engineering Test Loop (METL) liquid sodium facility at Argonne National Laboratory. The METL sodium purification system served as a representative system as it requires significant human in-the-loop interaction to accomplish its design function. The objective was to demonstrate how real-time operation could be automated while preserving oversight of the operator for ensuring that the system design functions are met. A digital twin model of the purification system was developed for both the cold trap purification loop and plugging meter diagnostic loop using information from the METL piping and instrumentation diagram (P&ID). Automated monitoring and diagnosis of component degradation in the METL facility was demonstrated in tests using the PRO-AID health monitoring software with the digital twin model incorporated in the library of components. Component failures were introduced and were successfully diagnosed in real time. These tests serve to demonstrate an advanced monitoring capability able to differentiate sensor degradation from component degradation, to generate a rank ordering of probabilities of different failure mechanisms that serves to circumvent the false alarm problem with current anomaly detection methods, and how facility monitoring can be transformed from anomaly detection to identification of a specific fault. Automated control of the purification system was demonstrated through simulations that exercised a model predictive controller designed using the digital twin model. Results of these simulations compared favorably with experimental data showing very good reference tracking response with negligible overshoot. In conclusion, these pilot tests and simulations successfully demonstrated the use of a digital twin for improved automation of monitoring and control. It was shown how the digital twin enables switching between control modes from cold trap operation where impurities are removed to plugging meter operation where impurity concentrations are measured.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

Additive Manufacturing of Self‐Sensing Carbon Fiber Composites

Carbon fiber-reinforced polymer (CFRP) composites have gained substantial attention across various industries owing to their exceptional mechanical properties and lightweight nature. The emergence of additive manufacturing technologies brings new opportunities to the industry, offering advantages such as design freedom, rapid prototyping, and customization. However, the fabrication of CFRP composites through 3D printing techniques poses challenges pertaining to low resolution and limitations in complex geometry realization. This work introduces digital light processing printing as a versatile, high-resolution method ideal for CFRP composite fabrication. Furthermore, the development and characterization of CFRP are focused on and the manipulation of mechanical properties through variations in matrix resins and fiber loadings is investigated, showcasing the versatility of CFRP composites for tailored applications. Additionally, the integration of self-sensing capabilities in CFRP structures is explored, which opens up opportunities for applications in smart components for automotive and structural health monitoring.

carbon fiber composites↗
DOE OSTI2024

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

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

36 MATERIALS SCIENCE↗
DOE OSTI2023

Field Results from New Tensor Borehole Optical Fiber Strainmeter Installations in Oklahoma and Utah

The time evolving strain field contains a wealth of information that can be used to interpret subsurface behavior. For example, injecting or removing fluids from reservoirs or aquifers causes deformation that can be used as a diagnostic signal in some cases, while it can interfere with geodetic interpretations in other cases. We've previously demonstrated the feasibility of measuring the strain tensor at a depth of 30m caused by injection into a reservoir at 530m. The observed strain signals were interpreted using four independent analytic and numerical methods that resulted in estimates of the poroelastic properties and geometry of the reservoir that was consistent with data from well logs. However, studies like these are only possible if these deformations can be reliably measured. Years of lab and field work has culminated in the development of a novel borehole strainmeter capable of resolving multiple components of strain using embedded optical fibers configured as Michelson interferometers. It features four horizontal gauges separated by 45° to resolve the horizontal strain tensor as well as a vertical strain gauge and a sixth null component for state-of-health monitoring. The downhole sensing package also includes an open pipe through its center for grout circulation during single-trip deployments and a fully welded stainless steel exterior for robustness and longevity. These instruments have a resolution of 2x10-13 strain that can easily measure the solid earth tides. Preliminary data are available from four strainmeters in shale at our Oklahoma site and four in compacted sand and gravel in Utah. These are deployed from 40-60m, except one of the strainmeters in Oklahoma is deployed at 500m. The data include strains from the initial grout curing, comparisons to predicted earth tide models and in-situ calibration results, barometric pressure admittances and spectral analyses as well as signals from underground injections and surface waves from teleseismic events. Preliminary analyses indicate behavior consistent with other strainmeter deployments, and comparison to data from a Gladwin strainmeter at the Oklahoma site validate the performance of the new design. Analyses from a suite of six well tests at the Oklahoma site show for the first time how the strain tensor field varies with location during well testing.

DeWolf, Scott↗
NASA NTRS1997

Ring Buffered Network Bus

This report describes the research effort to demonstrate the integration of a data sharing technology, Ring Buffered Network Bus, in development by Dryden Flight Research Center, with an engine simulation application, the Java Gas Turbine Simulator, in development at the University of Toledo under a grant from the Glenn Research Center. The objective of this task was to examine the application of the RBNB technologies as a key component in the data sharing, health monitoring and system wide modeling elements of the NASA Aviation Safety Program (AVSP) [Golding, 1997]. System-wide monitoring and modeling of aircraft and air safety systems will require access to all data sources which are relative factors when monitoring or modeling the national airspace such as radar, weather, aircraft performance, engine performance, schedule and planning, airport configuration, flight operations, etc. The data sharing portion of the overall AVSP program is responsible for providing the hardware and software architecture to access and distribute data, including real-time flight operations data, among all of the AVSP elements. The integration of an engine code capable of numerically "flying" through recorded flight paths and weather data using a software tool that allows for distributed access of data to this engine code demonstrates initial steps toward building a system capable of monitoring and modeling the National Airspace.

Source record↗
NASA NTRS2017

Communications and Intelligent Systems Division Overview

Provides expertise, and plans, conducts and directs research and engineering development in the competency fields of advanced communications and intelligent systems technologies for applications in current and future aeronautics and space systems.Advances communication systems engineering, development and analysis needed for Glenn Research Center's leadership in communications and intelligent systems technology. Focus areas include advanced high frequency devices, components, and antennas; optical communications, health monitoring and instrumentation; digital signal processing for communications and navigation, and cognitive radios; network architectures, protocols, standards and network-based applications; intelligent controls, dynamics and diagnostics; and smart micro- and nano-sensors and harsh environment electronics. Research and discipline engineering allow for the creation of innovative concepts and designs for aerospace communication systems with reduced size and weight, increased functionality and intelligence. Performs proof-of-concept studies and analyses to assess the impact of the new technologies.

Intelligent Systems↗