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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 793 records · Page 44
All sourcesNASA NTRSDOE OSTI
DOE OSTI2013

Scaling considerations for a multi-megawatt class supercritical CO2 brayton cycle and commercialization.

Small-scale supercritical CO2 demonstration loops are successful at identifying the important technical issues that one must face in order to scale up to larger power levels. The Sandia National Laboratories supercritical CO2 Brayton cycle test loops are identifying technical needs to scale the technology to commercial power levels such as 10 MWe. The small size of the Sandia 1 MWth loop has demonstration of the split flow loop efficiency and effectiveness of the Printed Circuit Heat Exchangers (PCHXs) leading to the design of a fully recuperated, split flow, supercritical CO2 Brayton cycle demonstration system. However, there were many problems that were encountered, such as high rotational speeds in the units. Additionally, the turbomachinery in the test loops need to identify issues concerning the bearings, seals, thermal boundaries, and motor controller problems in order to be proved a reliable power source in the 300 kWe range. Although these issues were anticipated in smaller demonstration units, commercially scaled hardware would eliminate these problems caused by high rotational speeds at small scale. The economic viability and development of the future scalable 10 MWe solely depends on the interest of DOE and private industry. The Intellectual Property collected by Sandia proves that the ~10 MWe supercritical CO2 power conversion loop to be very beneficial when coupled to a 20 MWth heat source (either solar, geothermal, fossil, or nuclear). This paper will identify a commercialization plan, as well as, a roadmap from the simple 1 MWth supercritical CO2 development loop to a power producing 10 MWe supercritical CO2 Brayton loop.

Fleming, Darryn D.↗
DOE OSTI2015

Imaging the behavior of molecules in biological systems: Breaking the 3D speed barrier with 3D multi-resolution microscopy

Here, the overwhelming effort in the development of new microscopy methods has been focused on increasing the spatial and temporal resolution in all three dimensions to enable the measurement of the molecular scale phenomena at the heart of biological processes. However, there exists a significant speed barrier to existing 3D imaging methods, which is associated with the overhead required to image large volumes. This overhead can be overcome to provide nearly unlimited temporal precision by simply focusing on a single molecule or particle via real-time 3D single-particle tracking and the newly developed 3D Multi-resolution Microscopy (3D-MM). Here, we investigate the optical and mechanical limits of real-time 3D single-particle tracking in the context of other methods. In particular, we investigate the use of an optical cantilever for position sensitive detection, finding that this method yields system magnifications of over 3000×. We also investigate the ideal PID control parameters and their effect on the power spectrum of simulated trajectories. Taken together, these data suggest that the speed limit in real-time 3D single particle-tracking is a result of slow piezoelectric stage response as opposed to optical sensitivity or PID control.

3D Multi-resolution microscopy↗
DOE OSTI2024

Development of an Optimal Variable-Pitch Controller for Floating Axial-Flow Marine Hydrokinetic Turbines: Preprint

This article discusses the development of an optimal variable-pitch controller for floating, axial-flow marine turbines. Recently, OpenFAST, an open-source wind turbine modeling tool, has been extended to model marine turbines. A controller is necessary to simulate marine turbines for different load cases using OpenFAST, which greatly impacts the performance of the energy system. Previous studies have designed controllers using a linearized model of the marine turbine, which can be timeconsuming and require the expertise of a control engineer. In this study, we use an automated approach that uses generic models of the marine turbine to identify the controller gains, which can expedite the process of designing a controller. Using an optimizer to identify the control system parameters can additionally improve the controller's performance. The optimal controller tuned using such an approach results in a 20% reduction in the towerbase damage equivalent loading and better tracking of the rated generator speed and power.

closed-loop control↗
DOE OSTI2022

Heavy Duty Natural Gas Single Cylinder Research Engine Installation, Commissioning, and Baseline Testing

Natural Gas (NG) Internal Combustion Engines (ICE) are a promising alternative to diesel engines for on-road heavy-duty applications to reduce greenhouse gas and harmful pollutant emissions. NG engines have not been widely adopted due to the lower thermal efficiency compared with diesel engine counterparts. To develop the base knowledge required to reach the desired efficiency, a Single Cylinder Engine (SCE) is the most effective platform to acquire reliable and repeatable data. A SCE test cell was developed using a Cummins 15-liter six-cylinder heavy-duty engine block modified to fire one cylinder (2.5-liter displacement). A Woodward Large Engine Control Module (LECM) is integrated to permit implementation of real-time advanced combustion control. Intake and exhaust characteristics, fuel composition, and exhaust gas recirculated substitution rate (EGR) are fully adjustable. A high-speed data acquisition system acquires in-cylinder, intake, and exhaust pressure for combustion analysis. The baseline testing shows reliable and consistent results for engine thermal efficiency, indicated mean effective pressure (IMEP), and coefficient of variance of the IMEP over a wide range of operating conditions while achieving effective control of all engine control and operation variables. This test cell will be used to conduct a research program to develop new and innovative control algorithms and CFD optimized combustion chamber designs, allowing ultra-high efficiency and low emissions for NG ICE heavy-duty on-road applications.

03 NATURAL GAS↗
DOE OSTI2012

Feedback control of an azimuthal oscillation in the E Multiplication-Sign B discharge of Hall thrusters

Feedback control of a low-frequency azimuthal wave known as a 'rotating spoke' in the E Multiplication-Sign B discharge of a cylindrical Hall thruster was demonstrated. The rotating spoke is an m = 1 azimuthal variation in density, electron temperature, and potential that rotates at about 10% of the local E Multiplication-Sign B electron rotation speed. It causes increased electron transport across the magnetic field and is suspected to be an ionization wave. Feedback control of this wave required special consideration because, although it causes a rotating azimuthal variation in the current density to the anode, it does not show up as a signal in the total thruster discharge current. Therefore, an extra source of information was needed to track the oscillation, which was addressed by using a special anode that was split azimuthally into four segments. The current to each segment oscillates as the rotating spoke passes over it, and feedback is accomplished by resistors connected in series with each anode segment which causes the voltage on a segment to decrease in proportion to the current through that segment. The feedback resulted in the disappearance of a coherent azimuthal wave and a decrease in the time-averaged total discharge current by up to 13.2%.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2012

Preliminary Experimental Results of Integrated Gasification Fuel Cell Operation Using Hardware Simulation

A newly developed integrated gasification fuel cell (IGFC) hybrid system concept has been tested using the Hybrid Performance (Hyper) project hardware-based simulation facility at the U.S. Department of Energy, National Energy Technology Laboratory. The cathode-loop hardware facility, previously connected to the real-time fuel cell model, was integrated with a real-time model of a gasifier of solid (biomass and fossil) fuel. The fuel cells are operated at the compressor delivery pressure, and they are fueled by an updraft atmospheric gasifier, through the syngas conditioning train for tar removal and syngas compression. The system was brought to steady state; then several perturbations in open loop (variable speed) and closed loop (constant speed) were performed in order to characterize the IGFC behavior. Coupled experiments and computations have shown the feasibility of relatively fast control of the plant as well as a possible mitigation strategy to reduce the thermal stress on the fuel cells as a consequence of load variation and change in gasifier operating conditions. Results also provided an insight into the different features of variable versus constant speed operation of the gas turbine section.

10 SYNTHETIC FUELS↗
DOE OSTI2012

LIDAR Wind Speed Measurements of Evolving Wind Fields

Light Detection and Ranging (LIDAR) systems are able to measure the speed of incoming wind before it interacts with a wind turbine rotor. These preview wind measurements can be used in feedforward control systems that are designed to reduce turbine loads. However, the degree to which such preview-based control techniques can reduce loads by reacting to turbulence depends on how accurately the incoming wind field can be measured. Past studies have assumed the validity of physicist G.I. Taylor’s 1938 frozen turbulence hypothesis, which implies that turbulence remains unchanged as it advects downwind at the mean wind speed. With Taylor’s hypothesis applied, the only source of wind speed measurement error is distortion caused by the LIDAR. This study introduces wind evolution, characterized by the longitudinal coherence of the wind, to LIDAR measurement simulations using the National Renewable Energy Laboratory’s (NREL’s) 5-megawatt turbine model to create a more realistic measurement model. A simple model of wind evolution was applied to a frozen wind field that was used in previous studies to investigate the effects of varying the intensity of wind evolution. LIDAR measurements were also evaluated using a large eddy simulation (LES) of a stable boundary layer that was provided by the National Center for Atmospheric Research.

17 WIND ENERGY↗
DOE OSTI2022

Data-driven model for divertor plasma detachment prediction

We present a fast and accurate data-driven surrogate model for divertor plasma detachment prediction leveraging the latent feature space concept in machine learning research. Our approach involves constructing and training two neural networks: an autoencoder that finds a proper latent space representation (LSR) of plasma state by compressing the multi-modal diagnostic measurements and a forward model using multi-layer perception (MLP) that projects a set of plasma control parameters to its corresponding LSR. By combining the forward model and the decoder network from autoencoder, this new data-driven surrogate model is able to predict a consistent set of diagnostic measurements based on a few plasma control parameters. In order to ensure that the crucial detachment physics is correctly captured, highly efficient 1D UEDGE model is used to generate training and validation data in this study. The benchmark between the data-driven surrogate model and UEDGE simulations shows that our surrogate model is capable of providing accurate detachment prediction (usually within a few per cent relative error margin) but with at least four orders of magnitude speed-up, indicating that performance-wise, it has the potential to facilitate integrated tokamak design and plasma control. Comparing with the widely used two-point model and/or two-point model formatting, the new data-driven model features additional detachment front prediction and can be easily extended to incorporate richer physics. This study demonstrates that the complicated divertor and scrape-off-layer plasma state has a low-dimensional representation in latent space. Understanding plasma dynamics in latent space and utilising this knowledge could open a new path for plasma control in magnetic fusion energy research.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2014

Synthesis of the unmanned aerial vehicle remote control augmentation system

Medium size Unmanned Aerial Vehicle (UAV) usually flies as an autonomous aircraft including automatic take-off and landing phases. However in the case of the on-board control system failure, the remote steering is using as an emergency procedure. In this reason, remote manual control of unmanned aerial vehicle is used more often during take-of and landing phases. Depends on UAV take-off mass and speed (total energy) the potential crash can be very danger for airplane and environment. So, handling qualities of UAV is important from pilot-operator point of view. In many cases the dynamic properties of remote controlling UAV are not suitable for obtaining the desired properties of the handling qualities. In this case the control augmentation system (CAS) should be applied. Because the potential failure of the on-board control system, the better solution is that the CAS algorithms are placed on the ground station computers. The method of UAV handling qualities shaping in the case of basic control system failure is presented in this paper. The main idea of this method is that UAV reaction on the operator steering signals should be similar - almost the same - as reaction of the 'ideal' remote control aircraft. The model following method was used for controller parameters calculations. The numerical example concerns the medium size MP-02A UAV applied as an aerial observer system.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2017

Reducing the stochasticity of crystal nucleation to enable subnanosecond memory writing

Operation speed is a key challenge in phase-change random-access memory (PCRAM) technology, especially for achieving subnanosecond high-speed cache memory. Commercialized PCRAM products are limited by the tens of nanoseconds writing speed, originating from the stochastic crystal nucleation during the crystallization of amorphous germanium antimony telluride (Ge 2 Sb 2 Te 5 ). Here, we demonstrate an alloying strategy to speed up the crystallization kinetics. The scandium antimony telluride (Sc 0.2 Sb 2 Te 3 ) compound that we designed allows a writing speed of only 700 picoseconds without preprogramming in a large conventional PCRAM device. This ultrafast crystallization stems from the reduced stochasticity of nucleation through geometrically matched and robust scandium telluride (ScTe) chemical bonds that stabilize crystal precursors in the amorphous state. Controlling nucleation through alloy design paves the way for the development of cache-type PCRAM technology to boost the working efficiency of computing systems.

Science & Technology - Other Topics↗
DOE OSTI2024

Development of an Optimal Variable-Pitch Controller for Floating Axial-Flow Marine Hydrokinetic Turbines

This article discusses the development of an optimal variable-pitch controller for floating, axial-flow marine turbines. Recently, OpenFAST, an open-source wind turbine modeling tool, has been extended to model marine turbines. A controller is necessary to simulate marine turbines for different load cases using OpenFAST, which greatly impacts the performance of the energy system. Previous studies have designed controllers using a linearized model of the marine turbine, which can be time-consuming and require the expertise of a control engineer. In this study, we use an automated approach that uses generic models of the marine turbine to identify the controller gains, which can expedite the process of designing a controller. Using an optimizer to identify the control system parameters can additionally improve the controller's performance. The optimal controller tuned using such an approach results in a 20% reduction in the tower-base damage equivalent loading and better tracking of the rated generator speed and power.

axial flow↗
DOE OSTI2014

Capability of Rolling Efficiency for 100M High-Speed Rails

OG Technologies, Inc. (OGT), along with its academic and industrial partners, proposes this CORE project for the Capability of Rolling Efficiency for 100m high-speed rails. The goal is to establish the competitive advantage, and thus the sustainability of the US-based rail manufacturers by greatly enhanced efficiency through innovative in-line metrology technology, in-depth process knowledge, and advanced process control to overcome detrimental factors such as higher labor costs that are saddling the US manufacturing sector. This Phase I project was carried out by an industrial-academia team over 9 months. The R&D team successfully completed all technical tasks and accomplished the objectives for the Phase I. In addition to the technical efforts, the introductory information of this project as well as anticipated progress was disseminated to steel mills interested in the project. The Phase I project has established the technical and commercial basis for additional development. There are needs to further completing the in-line sensing capability, deepening the capability of metamodeling, and supporting the process monitoring and control. The R&D team plans to submit a Phase II proposal based on the findings.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Electron Density Measurements Using USPR (Final Scientific/Technical Report)

UC Davis has fabricated an ultrashort pulse reflectometer (USPR) diagnostic instrument for electron density profile measurements on compact, short duration, magnetically-confined fusion-energy concept devices such as spheromaks and FRCs. The USPR system transmits extremely short duration (~few nsec) chirped waveforms that together span 29 to 75 GHz. These chirped waveforms illuminate and reflect from the target plasma, with each frequency component reflecting from a different density layer (higher frequencies probe deeper into the plasma before reflecting). The reflected waveforms are split into roughly 42 different frequencies; time-of-flight (TOF) measurements made at each frequency with high resolution (~25 psec measurement resolution which corresponds to ~5 mm). These TOF data may then be inverted via software to generate electron density profiles with high time resolution (~10 μsec). At the heart of the system is a field programmable gate array (FPGA) based controller which collects and processes all of the USPR data in addition to generating all of the control signals required for maximum flexibility. The FPGA controller has the software flexibility to be easily reconfigured for different plasma devices, and the entire system sufficiently compact to be easily and quickly transported between devices. A high speed impulse generator was transformed into a set of three ultrashort pulse transmitter chirps using a combination of dispersive waveguide, frequency doublers and high-pass filters. A mm-wave controller was fabricated to sequentially switch between the three chirps, directing the chirps one-by-one to three different mm-wave assemblies spanning 29-75 GHz. Each mm-wave assembly consists of a high power active multiplier chain which converts the transmitter chirp to higher frequencies, and a broadband mixer which downconverts the reflected waveform to the 2-18 GHz range of the UPSR receiver. The 16-channel receiver (shared by all 3 mm-wave assemblies) was fabricated employing custom TOF modules capable of operating at a high 1 MHz sampling rate. Laboratory testing of the full system revealed the presence of unwanted harmonics from the multiplication process, with interference observed in the downconverted reflections at selected frequency channels that could not be completely filtered out. Additional interference effects arising from internal reflections within the mm-wave assemblies were minimized using a high-speed switch which served to “gate out” much of these reflections. The USPR diagnostic was transported and installed onto the HIT-SIU plasma device, becoming operational on 11/08/2022. Although designed to span 3 distinct mm-wave bands, the HIT-SIU plasmas at this time were sufficiently low density such that only the lowest of the three bands was likely to have strong plasma reflections. The system was then set to operate on only the lowest band (assembly #1), with data collected every 1 μsec rather than 3 μsec which would have been the case when cycling through all three bands. Connected to HIT-SIU, time-varying plasma reflections were observed on 9 of 16 possible frequency channels. Close examination of the data collected revealed issues previously unobserved in laboratory testing, associated with (a) reflections from the small aperture horns required for operation within the HIT-SIU device, and (b) a dependence of the recorded TOF with the threshold voltage of a given channel. Plans were made to address each of these issues before undertaking any future campaigns.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Electrically Controlled All-Antiferromagnetic Tunnel Junctions on Silicon with Large Room-Temperature Magnetoresistance

Antiferromagnetic (AFM) materials are a pathway to spintronic memory and computing devices with unprecedented speed, energy efficiency, and bit density. Realizing this potential requires AFM devices with simultaneous electrical writing and reading of information, which are also compatible with established silicon-based manufacturing. Recent experiments have shown tunneling magnetoresistance (TMR) readout in epitaxial AFM tunnel junctions. However, these TMR structures are not grown using a silicon-compatible deposition process, and controlling their AFM order required external magnetic fields. Here are shown three-terminal AFM tunnel junctions based on the noncollinear antiferromagnet PtMn 3 , sputter-deposited on silicon. The devices simultaneously exhibit electrical switching using electric currents, and electrical readout by a large room-temperature TMR effect. First-principles calculations explain the TMR in terms of the momentum-resolved spin-dependent tunneling conduction in tunnel junctions with noncollinear AFM electrodes.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Coordinated Control of Wind Turbine and Energy Storage System for Reducing Wind Power Fluctuation

This paper proposes a coordinated control of wind turbine and energy storage system (ESS). Because wind power (WP) is highly dependent on variable wind speed and could induce a severe stability problem to power system especially when the WP has high penetration level. To solve this problem, many power generation corporations or grid operators recently use the ESS. It has very quick response and good performance for reducing the impact of WP fluctuation but has high cost for its installation. Therefore, it is very important to design the control algorithm considering both ESS capacity and grid reliability. Thus, we propose the control algorithm to mitigate the WP fluctuation by using the coordinated control between wind turbine and ESS considering ESS state of charge (SoC) and the WP fluctuation. From deloaded control according to WP fluctuation and ESS SoC management, we can expect the ESS lifespan expansion and improved grid reliability. The effectiveness of the proposed method is validated in MATLAB/Simulink considering power system including both wind turbine generator and conventional generators which react to system frequency deviation.

17 WIND ENERGY↗
DOE OSTI2015

A miniaturized piezoelectric turbine with self-regulation for increased air speed range

This paper presents the design and demonstration of a piezoelectric turbine with self-regulation for increased air speed range. The turbine's transduction is achieved by magnetic “plucking” of a piezoelectric beam by the passing rotor. The increased speed range is achieved by the self-regulating mechanism which can dynamically adjust the magnetic coupling between the magnets on the turbine rotor and the piezoelectric beam using a micro-spring. The spring is controlled passively by the centrifugal force of the magnet on the rotor. This mechanism automatically changes the relative position of the magnets at different rotational speeds, making the coupling weak at low airflow speeds and strong at high speeds. Hence, the device can start up with a low airflow speed, and the output power can be ensured when the airflow speed is high. A theoretical model was established to analyse the turbine's performance, advantages, and to optimize its design parameters. A prototype was fabricated and tested in a wind tunnel. The start-up airflow speed was 2.34 m/s, showing a 30% improvement against a harvester without the mechanism.

42 ENGINEERING↗
DOE OSTI2025

Examining future changes in coastal low-level jet properties offshore California through dynamical downscaling

The coastal low-level jet, or coastal low-level jet (CLLJ), is a synoptically-forced meteorological feature frequently present offshore the western United States (U.S.). Characterized by a wind speed maximum that resides at the top of the marine boundary layer, the CLLJ is largely controlled by the location and strength of the North Pacific High (NPH) as well as the coastal geometry. Considering the rich wind resource available in this offshore region, the Bureau of Ocean Energy Management identified wind energy lease areas offshore California and supported the deployment of two U.S. Department of Energy wind lidar buoys near Morro Bay and Humboldt. Despite our relatively good understanding of the fundamental mechanisms responsible for large-scale CLLJ properties offshore the western U.S., future changes in CLLJ characteristics are less clear. To address this research challenge, and ultimately to better inform future wind turbine deployments, we use simulations driven by three global climate models (GCMs). We apply self-organizing maps to the model outputs for a historical and two future climate periods to show the range of NPH regimes that support CLLJ conditions during the warm seasons, as well as the subtle contribution from land-falling cyclones approaching the mainland during the cold seasons. Compared to the historical period, the three GCM-driven simulations agree that CLLJ conditions will become more (less) prevalent from central California northward (southward). They agree less with respect to future changes in maximum CLLJ wind speeds and CLLJ heights. However, after considering model biases present during the historical period, wind speeds between the models are actually more similar during the 2070–2095 period than during the historical period. The potential combination of more frequent CLLJ conditions characterized by relatively consistent wind speeds occurring at lower heights across northern California suggests that the Humboldt lease area may be ideal for a long-term wind turbine deployment.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2018

Advanced SOFC quality control and the role of manufacturing defects on stack reliability

Atrex Energy rolled out first commercial SOFC generator products in 2013. Following that we embarked on implementation of mass production in order to ramp up productivity and lower the costs in the meantime. To ensure the goal of mass production, an accurate, cost effective and consistent quality control methodology needs to be in place. The aim of this DOE funded project is to devise a machine and methodology for cell quality control using modern non-destructive testing methods and cell rejection criterion based on the empirical determination of the role of manufacturing flaws on stack degradation and reliability. The work scope encompasses two goals aimed at 1) developing automatable techniques for objective flaw detection and 2) developing an understanding of the ramifications of flaws on stack and cell reliability. By accomplishing these two goals it is likely that an advanced stage Quality Control (QC) device can be developed. This project scope encompasses: 1) Invention of a high speed automated instrument for spatial mapping of surface and sub-surface imperfections in production cells (ex situ) using modern imaging techniques. 2) Identification of rejection criteria upon which to screen cells from production by: a. Magnification of the effect of production defects on cell degradation through fabrication and testing of micro-cells which encompass these imperfections. b. The long term testing of full size production cells both as single cells and in small stacks, in order to correlate the (in situ) performance and degradation with the imperfection type (identified ex-situ) and hence be able to classify imperfections as actual defects. We first built a defect library with the cells containing imperfections classified and documented. The cells with various imperfections were tested to evaluate the imperfection potential impact on cell electrochemical performance. Evaluations were conducted on minicell, single cell and stack levels. On minicell level, pinhole, scratch, crack, contamination, and pop-out were investigated. We found: (1) none of the imperfections causes calamity type failure, (2) pinholes do not show measurable effect on minicell performance, (3) imperfection such as electrolyte abrasion, scratch, and pop out cause minicell potential to fluctuate by different degrees; the cells with such imperfections exhibit sensitivity of potential to high fuel utilization and “self healing” behavior. On single cell level we evaluated the effect of long crack and high population pinholes. The cell with a long crack does not show performance compromise at start. There is no potential fluctuation or sensitivity to high fuel utilization or catastrophic failure. The voltage degradation due to thermal cycle is slightly higher than normal cells. The cells with high population pinholes perform surprisingly as well as normal cells over a period of 3,500h. Even when subjected to cyclic load condition, the cells 4 show negligible degradation. Our cells appear to have “self immunization” feature which fends off the adversary effects of certain imperfections. Defects were also evaluated on stack level. Two stacks were made each with ten defect cells. The first stack was tested for 13,2000h under steady load condition while the second was tested for 9,000h under transient load conditions. We found: (1) voltage fluctuation and sensitivity to thermal cycle were not observed in contrast to minicell test, (2) of the various cracks examined, including longitudinal cracks, circumferential crack, crack near closed and open ends, none exhibited distinguishable impact on performance, (3) defect cells exhibited higher degradation rates on average under steady load condition; Individually some defect cells performed similarly or better than reference cells, (4) under steady load condition all the cells degrade monotonically with degradation rate increasing with time, (5) under cyclic (transient) load condition, both defect and reference cells exhibit complex dynamic behaviors, (6) fuel loss (leak) was measured occasionally for stack 1, the cells with crack showed the highest fuel loss increase, nevertheless, no correlation with performance degradation could be established with certainty, and (7) no catastrophic failure ever happened other than incremental degradation. Posttest inspection and microanalysis were carried out; the observations are summarized in what follows: (1) Electrolyte pinholes, some scratches and IC porosity became undetectable after testing. (2) The cathode covering the popout defects is intact without any cracking or delamination. (3) The scratch was covered by cathode in pristine state; Ni oxide or NiO-YSZ filled the space where electrolyte was missing. After >10,000h operation, the cathode that used to cover the scratch was missing but the size of the scratch remains unchanged; there is a fairly dense Ni oxide layer on top of the scratch. (4) All of the cracks remain their original dimensions. Current collector kept longitudinal cracks closed which mitigated the adversary effect of crack on cell performance/durability. (5) The crack at open end showed some deterioration manifested by a small oxidation zone in the vicinity of the crack. Wide spectrum of imaging techniques were surveyed and evaluated to detect tubular SOFC defects. Optical methods, with and without assistance of expression technique, were applied to detect all kinds of defects. Thermograph method in combination of CO2 leak, ultra-sound and electric potential was also extensively evaluated to detect surface and under-surface defects such as short circuit. Based on these works, laser camera has been selected to build the final QC machine vision inspection system. The Gocator laser profile sensor was setup to generate 2D surface intensity images of tubular SOFC surface which were analyzed with Sherlock machine vision software supplied by Teledyne Dalsa. The Gocator output was integrated with the Sherlock software and enabled live images to be imported by a Common Vision Blox driver. The Sherlock software was programmed to detect various surface defects from the surface intensity images generated by the Gocator. These measurements are subsequently used to make pass or fail decisions.

01 COAL, LIGNITE, AND PEAT↗