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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
NASA NTRS2014

Progress of a Cross-Correlation Based Optical Strain Measurement Technique for Detecting Radial Growth on a Rotating Disk

The Aeronautical Sciences Project under NASA's Fundamental Aeronautics Program is interested in the development of novel measurement technologies, such as optical surface measurements for the in situ health monitoring of critical constituents of the internal flow path. In situ health monitoring has the potential to detect flaws, i.e. cracks in key components, such as engine turbine disks, before the flaws lead to catastrophic failure. The present study, aims to further validate and develop an optical strain measurement technique to measure the radial growth and strain field of an already cracked disk, mimicking the geometry of a sub-scale turbine engine disk, under loaded conditions in the NASA Glenn Research Center's High Precision Rotordynamics Laboratory. The technique offers potential fault detection by imaging an applied high-contrast random speckle pattern under unloaded and loaded conditions with a CCD camera. Spinning the cracked disk at high speeds (loaded conditions) induces an external load, resulting in a radial growth of the disk of approximately 50.0-μm in the flawed region and hence, a localized strain field. When imaging the cracked disk under static conditions, the disk will be undistorted; however, during rotation the cracked region will grow radially, thus causing the applied particle pattern to be 'shifted'. The resulting particle displacements between the two images is measured using the two-dimensional cross-correlation algorithms implemented in standard Particle Image Velocimetry (PIV) software to track the disk growth, which facilitates calculation of the localized strain field. A random particle distribution is adhered onto the surface of the cracked disk and two bench top experiments are carried out to evaluate the technique's ability to measure the induced particle displacements. The disk is shifted manually using a translation stage equipped with a fine micrometer and a hotplate is used to induce thermal growth of the disk, causing the particles to become shifted. For both experiments, reference and test images are acquired before and after the induced shifts, respectively, and then processed using PIV software. The controlled manual translation of the disk resulted in detection of the particle displacements accurate to ~1.75% of full scale and the thermal expansion experiment resulted in successful detection of the disk's thermal growth as compared to the calculated thermal expansion results. After validation of the technique through the induced shift experiments, the technique is implemented in the Rotordynamics Lab for preliminary assessment in a simulated engine environment. The discussion of the findings and plans for future work to improve upon the results are addressed in the paper.

rotordynamics↗
NASA NTRS2011

NASA Tech Briefs, August 2011

Topics covered include: Miniature, Variable-Speed Control Moment Gyroscope; NBL Pistol Grip Tool for Underwater Training of Astronauts; HEXPANDO Expanding Head for Fastener-Retention Hexagonal Wrench; Diagonal-Axes Stage for Pointing an Optical Communications Transceiver; Improvements in Speed and Functionality of a 670-GHz Imaging Radar; IONAC-Lite; Large Ka-Band Slot Array for Digital Beam-Forming Applications; Development of a 150-GHz MMIC Module Prototype for Large-Scale CMB Radiation; Coupling Between Waveguide-Fed Slot Arrays; PCB-Based Break-Out Box; Multiple-Beam Detection of Fast Transient Radio Sources; Router Agent Technology for Policy-Based Network Management; Remote Asynchronous Message Service Gateway; Automatic Tie Pointer for In-Situ Pointing Correction; Jitter Correction; MSLICE Sequencing; EOS MLS Level 2 Data Processing Software Version 3; DspaceOgre 3D Graphics Visualization Tool; Metallization for Yb14MnSb11-Based Thermoelectric Materials; Solvent/Non-Solvent Sintering To Make Microsphere Scaffolds; Enhanced Fuel-Optimal Trajectory-Generation Algorithm for Planetary Pinpoint Landing; Self-Cleaning Coatings and Materials for Decontaminating Field-Deployable Land and Water-Based Optical Systems; Separation of Single-Walled Carbon Nanotubes with DEP-FFF; Li Anode Technology for Improved Performance; Post-Fragmentation Whole Genome Amplification-Based Method; Microwave Tissue Soldering for Immediate Wound Closure; Principles, Techniques, and Applications of Tissue Microfluidics; Robotic Scaffolds for Tissue Engineering and Organ Growth; Stress-Driven Selection of Novel Phenotypes; Method for Accurately Calibrating a Spectrometer Using Broadband Light; Catalytic Microtube Rocket Igniter; Stage Cylindrical Immersive Display; Vacuum Camera Cooler; Atomic Oxygen Fluence Monitor; Thermal Management Tools for Propulsion System Trade Studies and Analysis; Introduction to Physical Intelligence; Technique for Solving Electrically Small to Large Structures for Broadband Applications; Accelerated Adaptive MGS Phase Retrieval; Large Eddy Simulation Study for Fluid Disintegration and Mixing; Tropospheric Correction for InSAR Using Interpolated ECMWF Data and GPS Zenith Total Delay; Technique for Calculating Solution Derivatives With Respect to Geometry Parameters in a CFD Code; Acute Radiation Risk and BRYNTRN Organ Dose Projection Graphical User Interface; Probabilistic Path Planning of Montgolfier Balloons in Strong, Uncertain Wind Fields; Flight Simulation of ARES in the Mars Environment; Low-Outgassing Photogrammetry Targets for Use in Outer Space; Planning the FUSE Mission Using the SOVA Algorithm; Monitoring Spacecraft Telemetry Via Optical or RF Link; and Robust Thermal Control of Propulsion Lines for Space Missions.

Source record↗
NASA NTRS1996

Design and Laboratory Validation of a Capacitive Sensor for Measuring the Recession of Thin-Layered Ablator

Flight vehicles are typically instrumented with subsurface thermocouples to estimate heat transfer at the surface using inverse analysis procedures. If the vehicle has an ablating heat shield, however, temperature time histories from subsurface thermocouples no longer provide enough information to estimate heat flux at the surface. In this situation, the geometry changes and thermal energy leaves the surface in the form of ablation products. The ablation rate is required to estimate heat transfer to the surface. A new concept for a capacitive sensor has been developed to measure ablator depth using the ablator's dielectric effect on a capacitor's fringe region. Relying on the capacitor's fringe region enables the gage to be flush mounted in the vehicle's permanent structure and not intrude into the ablative heat shield applied over the gage. This sensor's design allows nonintrusive measurement of the thickness of dielectric materials, in particular, the recession rates of low-temperature ablators applied in thin (0.020 to 0.060 in. (0.05 to 0.15 mm)) layers. Twenty capacitive gages with 13 different sensing element geometries were designed, fabricated, and tested. A two-dimensional finite-element analysis was performed on several candidate geometries. Calibration procedures using ablator-simulating shims are described. A one-to-one correspondence between system output and dielectric material thickness was observed out to a thickness of 0.055 in. (1.4 mm) for a material with a permittivity about three times that of air or vacuum. A novel method of monitoring the change in sensor capacitance was developed. This technical memorandum suggests further improvements in gage design and fabrication techniques.

Gregory K Noffz↗
NASA NTRS2011

Development of a Novel Self-Enclosed Sample Preparation Device for DNA/RNA Isolation in Space

Modern biology techniques present potentials for a wide range of molecular, cellular, and biochemistry applications in space, including detection of infectious pathogens and environmental contaminations, monitoring of drug-resistant microbial and dangerous mutations, identification of new phenotypes of microbial and new life species. However, one of the major technological blockades in enabling these technologies in space is a lack of devices for sample preparation in the space environment. To overcome such an obstacle, we constructed a prototype of a DNA/RNA isolation device based on our novel designs documented in the NASA New Technology Reporting System (MSC-24811-1/3-1). This device is self-enclosed and pipette free, purposely designed for use in the absence of gravity. Our design can also be modified easily for preparing samples in space for other applications, such as flowcytometry, immunostaining, cell separation, sample purification and separation according to its size and charges, sample chemical labeling, and sample purification. The prototype of our DNA/RNA isolation device was tested for efficiencies of DNA and RNA isolation from various cell types for PCR analysis. The purity and integrity of purified DNA and RNA were determined as well. Results showed that our developed DNA/RNA isolation device offers similar efficiency and quality in comparison to the samples prepared using the standard protocol in the laboratory.

Zhang, Ye↗
NASA NTRS2013

Investigation of a Cross-Correlation Based Optical Strain Measurement Technique for Detecting radial Growth on a Rotating Disk

The Aeronautical Sciences Project under NASA`s Fundamental Aeronautics Program is extremely interested in the development of novel measurement technologies, such as optical surface measurements in the internal parts of a flow path, for in situ health monitoring of gas turbine engines. In situ health monitoring has the potential to detect flaws, i.e. cracks in key components, such as engine turbine disks, before the flaws lead to catastrophic failure. In the present study, a cross-correlation imaging technique is investigated in a proof-of-concept study as a possible optical technique to measure the radial growth and strain field on an already cracked sub-scale turbine engine disk under loaded conditions in the NASA Glenn Research Center`s High Precision Rotordynamics Laboratory. The optical strain measurement technique under investigation offers potential fault detection using an applied high-contrast random speckle pattern and imaging the pattern under unloaded and loaded conditions with a CCD camera. Spinning the cracked disk at high speeds induces an external load, resulting in a radial growth of the disk of approximately 50.0-im in the flawed region and hence, a localized strain field. When imaging the cracked disk under static conditions, the disk will be undistorted; however, during rotation the cracked region will grow radially, thus causing the applied particle pattern to be .shifted`. The resulting particle displacements between the two images will then be measured using the two-dimensional cross-correlation algorithms implemented in standard Particle Image Velocimetry (PIV) software to track the disk growth, which facilitates calculation of the localized strain field. In order to develop and validate this optical strain measurement technique an initial proof-of-concept experiment is carried out in a controlled environment. Using PIV optimization principles and guidelines, three potential speckle patterns, for future use on the rotating disk, are developed and investigated in the controlled experiment. A range of known shifts are induced on the patterns; reference and data images are acquired before and after the induced shift, respectively, and the images are processed using the cross-correlation algorithms in order to determine the particle displacements. The effectiveness of each pattern at resolving the known shift is evaluated and discussed in order to choose the most suitable pattern to be implemented onto a rotating disk in the Rotordynamics Lab. Although testing on the rotating disk has not yet been performed, the driving principles behind the development of the present optical technique are based upon critical aspects of the future experiment, such as the amount of expected radial growth, disk analysis, and experimental design and are therefore addressed in the paper.

Clem, Michelle M.↗
DOE OSTI2023

A novel in-situ Raman spectroscopic cell for aqueous geochemistry at the solid–liquid interface

In-situ Raman spectroscopy has the potential to be a powerful technique for monitoring geochemical reactions at a solid–liquid interface in real time. In this article, we present the development and testing of an in-situ Raman spectroscopic cell, which can be used for reaction systems at moderate temperatures and pressure [<1000 psi (6.89 MPa), <100 °C, relevant to subsurface geologic systems] and can hold samples large enough for chemical mapping of heterogeneous rock surfaces. The system is validated by measuring the temperature-dependent conversion of gypsum to calcite over time. Near total conversion of gypsum to calcite on the mineral surface took 29 hours at room temperature and 150 minutes at 100 °C, corresponding to an 11.6-fold increase in the conversion rate. Further, we anticipate that this cell can be an important tool in quantifying the rates of carbon mineralization relevant to geologic carbon sequestration, particularly for the elevated rates recently observed in mafic/ultramafic rocks.

47 OTHER INSTRUMENTATION↗
DOE OSTI2024

A Novel Authentication Management for the Data Security of Smart Grid

Bidirectional wireless communication is employed in various smart grid components such as smart meters and control and monitoring applications where security is vital. The Trusted Third Party (TTP) and wireless connectivity between the smart meter and the third party in the key management-based encryption techniques for the smart grid are expected to be totally trustworthy and dependable. In a wired/wireless medium, however, a man-in-the-middle may seek to disrupt, monitor and manipulate the network, or simply execute a replay attack, revealing its vulnerability. Recognizing this, this study presents a novel authentication management (model) comprised of two layer security schema. The first layer implements an efficient novel encryption method for secure data exchange between meters and control center with the help of two partially trusted simple servers (constitutes the TTP). In this setting, one server handles the data encryption between the meter and control center/central database, and the other server administers the random sequence of data transmission. The second layer monitors and verifies exchanged data packets among smart meters. It detects abnormal packets from suspicious sources. To implement this node-to-node authentication, One class support vector machine algorithm is proposed which takes advantages of the location information as well as the data transmission history (node identification, packet size, and data transmission frequency). This schema secures data communication, and imposes a comprehensive privacy throughout the system without considerably extending the complexity of the conventional key management scheme.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2024

Live State of Health Monitoring of Inverter Subsystems

This presentation talks about different failure modes and corresponding detection schemes of PV panels, PV inverters, electric machines such as motors and power converter. Several novel techniques have been presented that are capable of measuring degradation as well as detecting faults in various location in a PV based power system.

ENGINEERING,SOLAR ENERGY↗
DOE OSTI2020

Illumination of Damage in Intact Rocks by Ultrasonic Transmission-Reflection and Digital Image Correlation

aboratory-scale experiments on intact rocks are critical to the development of physics-based fundamental understanding of various geophysical phenomena. In this work, the capability of ultrasonic wave transmission (T-mode) and reflection (R-mode) to monitor damage progression in uniaxially loaded prismatic intact rock specimens has been analyzed, as it is imperative to study the observations and document the capabilities of these techniques in a controlled environment. This study is novel in the sense that the R-mode linear ultrasonic testing (LUT) has been rarely employed in studying intact rock damage processes in a laboratory setting, with most of the studies utilizing a direct transmission (T-mode) approach or focusing on macroscopically fractured material. The two-dimensional digital image correlation (2-D DIC) full-field strain measurement approach was also used in-sync with the LUT monitoring to explicitly correlate the stress-induced damage in the specimens with the changes observed in the ultrasonic (T-mode and R-mode) signals. The results show that both the T-mode and R-mode LUT approaches are sensitive to detect the evolution of tensile and shear damage in the specimens, with the R-mode ultrasonic signals showing higher degree of sensitivity to the damage in the rocks, immediately following the initiation of damage in the rock volume.

58 GEOSCIENCES↗
DOE OSTI2024

Nontraditional Sensors for Aqueous Separation Research & Workforce Development

Idaho National Laboratory’s (INL) nuclear fuel cycle capabilities enable the deployment of technologies that sustain the current reactor fleet, support demonstration and deployment of new advanced reactors, and facilitate management and disposition of existing and future radiological waste materials. INL focuses on deploying nuclear energy systems with confidence by decreasing proliferation risk through research that demonstrates process transparency and supports safeguards and security by design. An example of these capabilities is the Beartooth test bed, set to begin operations toward the end of fiscal year 2026. Beartooth will include a cascade of centrifugal contactors, glove box lines, and solidification and dissolution equipment to aid in the progression of novel separation techniques and to provide hands-on experience to cultivate and maintain a robust workforce of experts. To support Beartooth’s enhanced instrumentation and monitoring equipment needs, several nontraditional sensors are being considered for future deployment. The non-traditional sensors include accelerometers, acoustic microphones, and infrared cameras. These nontraditional sensors have the potential to not only help monitor the process but also enhance nuclear safeguards.

98 - NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL↗
NASA NTRS1999

"Novel Techniques in Non-Stationary Analysis of Rotorcraft Vibration Signitures"

This research effort produced new methods to analyze the performance of linear predictors that track non-stationary processes. Specifically, prediction methods have been applied to the vibration pattern of rotorcraft drivetrains. This analysis is part or a larger rotorcraft Health and Usage Monitoring System (HUMS) that can diagnose immediate failures of the subsystems, as indicated by abrupt change in the vibration signature, and prognosticate future health, by examining the vibration patterns against long-term trends. This problem is described by a earlier joint paper co-authored by members of the funding agency and the recipient institutions prior to this grant effort. Specific accomplishments under this grant include the following: (1) Definition of a framework for analysis of non-stationary time-series estimation using the coefficients of an adaptive filter. (2) Description of a novel method of combining short-term predictor error and long-term regression error to analyze the performance of a non-stationary predictor. (3) Formulation of a multi-variate probability density function that quantifies the performance of a adaptive predictor by using the short- and long-term error variables in a Gamma function distribution. and (4) Validation of the mathematical formulations with empirical data from NASA flight tests and simulated data to illustrate the utility beyond the domain of vibrating machinery.

Meng, Teresa↗
DOE OSTI2023

Methods for the Automated Determination of Sustained Maximum Amplitudes in Oscillating Signals

Machine condition monitoring has been proven to reduce machine downtime and increase productivity. The state-of-the-art research uses vibration monitoring for tasks such as maintenance and tool wear prediction. A less explored aspect is how vibration monitoring might be used to monitor equipment sensitive to vibration. In a manufacturing environment, one example of where this might be needed is in monitoring the vibration of optical linear encoders used in high-precision machine tools and coordinate measuring machines. Monitoring the vibration of sensitive equipment presents a unique case for vibration monitoring because an accurate calculation of the maximum sustained vibration is needed, as opposed to extracting trends from the data. To do this, techniques for determining sustained peaks in vibration signals are needed. Here, this work fills this gap by formalizing and testing methods for determining sustained vibration amplitudes. The methods are tested on simulated signals based on experimental data. Results show that processing the signal directly with the novel Expire Timer method produces the smallest amounts of error on average under various test conditions. Additionally, this method can operate in real-time on streaming vibration data.

Industrial Internet of Things↗
NASA NTRS2021

Depletion & Recovery of the O3 Layer Observed from Space Over the Past 50 Years of the Anthropocene

This year we are celebrating the 50th anniversary of the launch of the backscatter UV (BUV) instrument on NASA’s Nimbus-4 satellite. Since then 10 more advanced instruments, but based on the same basic measurement principle, have been launched on polar orbiting NASA and NOAA satellites. The datasets produced by these instruments are unique for they have captured the period before the onset of the decline of the ozone layer due to manmade chemicals, the declining period, and the present slow recovery period. This period includes the rapid development of the iconic anthropocene era feature called the “Ozone Hole” . However, stitching together data from 11 separate satellite instruments to create a homogeneous record has presented many challenges. The first two NASA instruments suffered considerable degradation after launch that required the development of novel techniques to characterize their calibration. The next 7 instruments were launched on NOAA’s polar orbiting weather satellites that were not designed for long-term monitoring of climate variables. In particular, they didn’t have the station keeping capabilities needed to maintain a stable equator crossing time. Drifting orbits not only stress the retrieval algorithm and the calibration system of UV instruments but also make the interpretation of data difficult because the upper stratospheric ozone has systematic and complex diurnal variabilities that are comparable to the anthropogenic signal one wants to extract. We will highlight our recent efforts in untangling this knot. Finally, we will discuss the results from the OMPS limb scattering instrument, a recent addition to this constellation, that has been operating on the Suomi NPP satellite since October 2011. It is helping us capture how the ozone layer in the lower stratosphere and troposphere is evolving in response to the climate change and rising chemical pollutants in some parts of the world, while the upper stratosphere slowly recovers due to phaseout of the chemicals that initiated the decline of the ozone layer in the late 70s.

P Bhartia↗
NASA NTRSDate not supplied

Multi-Spectral Lidar Observations and Balloon Borne Validation of SO 2 -O 3 During the SOWLETS Campaign: An Examination of Local Incinerator Plume

The Langley Mobile O3 Lidar (LMOL) was stationed at NASA's Langley Research Center for the initiation of the SO 2 -O 3 Water Land Environment study (SOWLETS). The primary focus of the campaign was to examine the capabilities of a novel four-wavelength detection technique to measure the concentrations of sulfur dioxide (SO2) and ozone (O3). The exact location of the lidar, near the NASA/CAPABLE site, was optimized to intercept the plume emissions from a proximate incinerator facility using historical weather data for the month of the campaign. A novel four-wavelength lidar technique focused on the detection of sulfur dioxide (SO2) and ozone (O3) was employed, and its capabilities were thoroughly examined. The technique is built upon the standard DIAL. While 3 wavelengths would be enough to retrieve both SO2 and O3, the 4 wavelengths allow to provide data on aerosol backscattering. In parallel, SO 2 -O 3 sondes were launched and installed in the nearby NASA Landing and Impact research facility, providing validation for the lidar's atmospheric measurements. In conclusion, this campaign offers an improved understanding of SO2 emissions in the local environment and a validation of a novel technique to facilitate pollution observations. It shows the promise of this new kind of lidar to better understand and validate the observations by NASA/TEMPO ("Tropospheric Emissions: Monitoring of Pollution").

G. Gronoff↗
NASA NTRS2013

Optical Strain and Crack-Detection Measurements on a Rotating Disk

The development of techniques for the in-situ measurement and structural health monitoring of the rotating components in gas turbine engines is of major interest to NASA. As part of this on-going effort, several experiments have been undertaken to develop methods for detecting cracks and measuring strain on rotating turbine engine like disks. Previous methods investigated have included the use of blade tip clearance sensors to detect the presence of cracks by monitoring the change in measured blade tip clearance and analyzing the combined disk-rotor system's vibration response. More recently, an experiment utilizing a novel optical Moiré based concept has been conducted on a subscale turbine engine disk to demonstrate a potential strain measurement and crack detection technique. Moiré patterns result from the overlap of two repetitive patterns with slightly different spacing. When this technique is applied to a rotating disk, it has the potential to allow for the detection of very small changes in spacing and radial growth in a rotating disk due to a flaw such as a crack. This investigation was a continuation of previous efforts undertaken in 2011-2012 to validate this optical concept. The initial demonstration attempted on a subscale turbine engine disk was inconclusive due to the minimal radial growth experienced by the disk during operation. For the present experiment a new subscale Aluminum disk was fabricated and improvements were made to the experimental setup to better demonstrate the technique. A circular reference pattern was laser etched onto a subscale engine disk and the disk was operated at speeds up to 12 000 rpm as a means of optically monitoring the Moiré created by the shift in patterns created by the radial growth due the presence of the simulated crack. Testing was first accomplished on a clean defect free disk as a means of acquiring baseline reference data. A notch was then machined in to the disk to simulate a crack and testing was repeated for the purposes of demonstrating the concept. Displacement data was acquired using external blade tip clearance and shaft displacement sensors as a means of confirming the optical data and for validating other sensor based crack detection techniques.

Woike, Mark↗
NASA NTRS2013

Optical Strain and Crack-Detection Measurements on a Rotating Disk

The development of techniques for the in-situ measurement and structural health monitoring of the rotating components in gas turbine engines is of major interest to NASA. As part of this on-going effort, several experiments have been undertaken to develop methods for detecting cracks and measuring strain on rotating turbine engine like disks. Previous methods investigated have included the use of blade tip clearance sensors to detect the presence of cracks by monitoring the change in measured blade tip clearance and analyzing the combined disk-rotor system's vibration response. More recently, an experiment utilizing a novel optical Moiré based concept has been conducted on a subscale turbine engine disk to demonstrate a potential strain measurement and crack detection technique. Moiré patterns result from the overlap of two repetitive patterns with slightly different spacing. When this technique is applied to a rotating disk, it has the potential to allow for the detection of very small changes in spacing and radial growth in a rotating disk due to a flaw such as a crack. This investigation was a continuation of previous efforts undertaken in 2011 to 2012 to validate this optical concept. The initial demonstration attempted on a subscale turbine engine disk was inconclusive due to the minimal radial growth experienced by the disk during operation. For the present experiment a new subscale Aluminum disk was fabricated and improvements were made to the experimental setup to better demonstrate the technique. A circular reference pattern was laser etched onto a subscale engine disk and the disk was operated at speeds up to 12 000 rpm as a means of optically monitoring the Moiré created by the shift in patterns created by the radial growth due the presence of the simulated crack. Testing was first accomplished on a clean defect free disk as a means of acquiring baseline reference data. A notch was then machined in to the disk to simulate a crack and testing was repeated for the purposes of demonstrating the concept. Displacement data was acquired using external blade tip clearance and shaft displacement sensors as a means of confirming the optical data and for validating other sensor based crack detection techniques.

Woike, Mark↗
DOE OSTI2022

A Novel Approach for Real-Time Quality Monitoring in Machining of Aerospace Alloy through Acoustic Emission Signal Transformation for DNN

Gamma titanium aluminide (γ-TiAl) is considered a high-performance, low-density replacement for nickel-based superalloys in the aerospace industry due to its high specific strength, which is retained at temperatures above 800 °C. However, low damage tolerance, i.e., brittle material behavior with a propensity to rapid crack propagation, has limited the application of γ-TiAl. Any cracks introduced during manufacturing would dramatically lower the useful (fatigue) life of γ-TiAl components, making the workpiece surface’s quality from finish machining a critical component to product quality and performance. To address this issue and enable more widespread use of γ-TiAl, this research aims to develop a real-time non-destructive evaluation (NDE) quality monitoring technique based on acoustic emission (AE) signals, wavelet transform, and deep neural networks (DNN). Previous efforts have opted for traditional approaches to AE signal analysis, using statistical feature extraction and classification, which face challenges such as the extraction of good/relevant features and low classification accuracy. Hence, this work proposes a novel AI-enabled method that uses a convolutional neural network (CNN) to extract rich and relevant features from a two-dimensional image representation of 1D time-domain AE signals (known as scalograms), subsequently classifying the AE signature based on pedigreed experimental data and finally predicting the process-induced surface quality. The results of the present work show good classification accuracy of 80.83% using scalogram images, in-situ experimental data, and a VGG-19 pre-trained neural network, establishing the significant potential for real-time quality monitoring in manufacturing processes.

36 MATERIALS SCIENCE↗