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All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

recon3d

SAND2025-00533O recon3d is a software tool that provides automated 3D reconstruction and meshing capabilities. It processes labeled 3D image data from various sources, starting from image stacks, and calculates 3D feature distributions like size, shape, and location. The software also has tools for downscaling rectilinear grid data and creating tetrahedral meshes directly from image data. recon3d can be used by novice users via the command line with a properly formatted configuration file. Sandia National Laboratories is a multimission laboratory managed and operated by National Technology & Engineering Solutions of Sandia, LLC, a wholly owned subsidiary of Honeywell International Inc., for the U.S. Department of Energy’s National Nuclear Security Administration under contract DE-NA0003525.

Emery, John↗
DOE OSTI2025

Dark-field X-ray microscopy with structured illumination for three-dimensional imaging

Dark-field X-ray microscopy is a lens-based technique that enables real-space imaging of heterogeneous micro- and meso-scale ordered materials. However, achieving accurate three-dimensional (3D) reconstruction often requires meticulous sample alignment or rastering, requiring complex rotational setups and extended acquisition times. To address these challenges, we introduce a structured illumination technique optimized for 3D imaging of ordered materials at sub-micrometer length scales. Our approach employs a coded aperture to spatially modulate the incident X-ray beam, enabling 3D structural reconstruction from images captured at various aperture positions. Unlike current 3D imaging approaches, which often rely on rotational or rastering methods, our technique uses scanning X-ray silhouettes of the coded aperture for depth resolution along the diffraction axis. This eliminates the need for sample rotation or rastering, resulting in a highly stable and efficient imaging modality. We validated the efficacy of this approach through experimental imaging of an isolated twin domain within a bulk single crystal of an iron pnictide using a dark-field X-ray microscope. This advancement aligns with the enhanced brightness upgrades of modern synchrotron radiation facilities, unlocking new possibilities for high-resolution imaging of ordered materials.

47 OTHER INSTRUMENTATION↗
DOE OSTI2026

ML-based Micro-CT SOFC Microstructure Models (from Kent 2026 Microstructural Augmentation paper)

Overview -------------------------- This repository contains datasets from the manuscript **"Enhanced Generalizability to Deep-Learning Quantification of 3D Microstructural Characteristics through Microstructurally Aware Augmentation of Scarce Data"** (*William F. Kent, Rochan Bajpai, Rachel C. Kurchin, William K. Epting, Harry W. Abernathy, Paul A. Salvador. Submitted 2026*). The methods are also described in the dissertation **Data Intensive Analysis of Solid Oxide Cell Microstructures** (*Doctoral dissertation, Carnegie Mellon University, 2025*). The datasets here are trained convolutional neural network (CNN) models for predicting key microstructural properties of solid oxide cell (SOC) electrodes from low-res, 2-channel 3D images, as well as some helpful code. The parameters for input images are provided in the paper. Sample data is provided in the file `Combined_anode_aug_dual_1k_examples` - that particular data was used to train `anode_all_aug.pth` and will work most accurately with that model. Please familiarize yourself with all caveats on accuracy and applicability, as detailed in the associated paper. Usage -------------------------- The basic usage is as follows, assuming `model_fn` is the path to the .pth file, and `X` is 2-channel input image(s) of the proper dimensions (either one image of shape `[2,12,24,24]`, or a batch of N input images of shape `[N,2,12,24,24]`): from CNN_inferencer import load_model_for_inference model = load_model_for_inference(model_fn) y_predicted = model(X) The model object automatically handles input scaling and output de-scaling based on the way the models were trained - in other words, pass in a 2-channel micro-CT image, and it will output microstructural property values in real units. ## Other model object attributes Note that model has useful attributes other than its forward pass model(X). * `model.output_descaler` - returns the output descaler object. Model does the de-scaling when generating inferences, but you may want to re-use this de-scaler on other values to e.g. compare predictions to ground truth from already-scaled training data. * `model.prop_names` - Gives the property names of the predicted y values, in order. Only exists if there's an output scaler as part of the model object, which there will be in the models provided here. ## Usage with sample data Here is a short script to use with the included sample data. from CNN_inferencer import display_predictions, load_model_for_inference, calculate_mape, parity_plot import h5py import numpy as np model_fn = 'anode_all_aug.pth' data_fn = 'Combined_anode_aug_dual_1k_examples.h5' N_samples = 200 figure_outdir = '.' model = load_model_for_inference(model_fn) with h5py.File(data_fn,'r') as f: XX = f['X'] #These are the 2-channel 3D images yy = f['y'] #These are the ground-truth microstructural properties, but they have been scaled for training - need to de-scale below N = XX.shape[0] #How many images total in the input data file #Run inferences on N_samples random samples from XX. #Run in a batch, much more efficient than one at a time. ii = np.random.choice(N,N_samples,replace=False) ii.sort() y_pred = model(XX[ii]) #Get the original/true (but normalized/scaled) values from the training dataset... #Because they were normalized, they are not in real units yet. So let's also de-scale them using model.output_scaler. y_true = model.output_scaler.transform(yy[ii]) #Let's display actual values for just 5 random ones for i in np.random.choice(N_samples,5,replace=False): display_predictions(y_true[i], y_pred[i], model.prop_names) #Make parity plots for each property (ground truth vs predicted values) #Also label each plot with the mean abs. percent error (MAPE) of the predicted values for i,key in enumerate(model.prop_names): mape = calculate_mape(y_true[:,i], y_pred[:,i]) parity_plot(y_true[:,i], y_pred[:,i], figure_outdir, key, extra_title=f' ({mape:.2f}% MAPE)')

3D microstructure↗
DOE OSTI2022

Development of green-colour-emitting pyrotechnics as a core for 3D temperature imaging sensors inside coal boilers

Efficiency in the control operation of the boilers for coal and coal with biomass can be further improved if the flue gas temperature distribution can be better characterized. This is very difficult in these harsh environmental systems, where spatially resolved measurements are nearly impossible with solid-state sensors. Here, in this work, we evaluate the development of pyrotechnic compounds that would serve as the basis for a novel optical mapping of the temperature inside coal boilers. For this purpose, various green-colour-emitting pyrotechnics using BaCl 2 · 2H 2 O and Ba(NO 3 ) 2 as the green light source were prepared, as this colour offers a distinct signal from the combustion-based background in the boiler. These pyrotechnics were characterized using thermogravimetric analysis (TGA) and X-ray diffraction (XRD) and tested using a flat-flame burner. Furthermore, the composition was varied to evaluate the effect of different metal fuels such as Sn, Co, and Mg, as well as various binders such as ethylcellulose, shellac, parlon, and PVC on green light emission. The emission intensity and the apparent ignition temperature were strongly dependent on the metal type, with Mg showing higher intensities. On the other hand, the effect of the binder showed that the ignition behaviour, emission intensity, and spectral purity were influenced by the nature and exothermicity of the binder. The addition of other potential green light-producing materials, such as boric acid, increased the intensity of emission by 17% for a BaCl 2 · 2H 2 O-based composition. This study identified prospective compositions with intense and bright green-colour emissions that have high spectral purities.

42 ENGINEERING↗
DOE OSTI2022

3D magnetic imaging using electron vortex beam microscopy

Abstract Electron vortex beams are free-electron waves that carry orbital angular momentum. There has been growing theoretical and experimental interest in the use of electron vortex beams as a tool for the investigation of magnetic materials. However, due to the complex wavefront of the propagating waves, a deeper understanding of the interaction of electron vortex beams and the magnetic sample is needed. Here we calculate the magnetic phase shift that an electron vortex beam obtains upon transmitting through a magnetic sample. We show that this magnetic phase shift is influenced by the out-of-plane magnetization, which is a unique characteristic of incident electron vortex beams and is proportional to their orbital angular momentum. Finally, we develop a phase retrieval methodology to retrieve the out-of-plane component of magnetization. Based on our theory, we discuss suitable experimental conditions that would enable this imaging capability for magnetic materials and further extend to non-magnetic chiral materials.

47 OTHER INSTRUMENTATION↗
DOE OSTI2020

Model and Standard Operating Procedures Supporting Signal Variation Flow Graph Analysis

This document will describe the principles of the Signal Variation Flow Technique, and the uncertainty models generated using it. We focus on the capture of the variation between the ideal signal and the measured signal. The ideal signal is defined to represent the signal output of a system whose full state behavior is known, with no variation in environment or during operation, and whose photons trajectories are not modified by the object. A CT uncertainty analysis is the result of two main steps. First, the radiography regime extends from the source to the collected image, which is 2D in the case of standard CT. This maps all upstream uncertainties into the variation observed on the radiograph and captures all variation in the physical domain. Second, the reconstruction regime extends from the captured images to the reconstructed 3D image. This regime is purely in the mathematical domain and corrects reconstruction algorithm artifacts/anomalies. The present work focuses on building the model through the radiography regime. The reconstruction regime is expected to be largely a study of algorithmic sensitivity, requiring the definition of a range of standardized tests through which the algorithms would be run. Radiographic variation would then be mapped through reconstruction sensitivities to predict the signal variation in the final image. An incomplete list for the reconstructed image variation output basis includes voxel density, edge blur and length variation, in analogous fashion to the basis functions presented in this work. The signal variation occurs in several forms at the radiograph. These forms are gathered into a complete basis set of functions describing all variation on the radiograph. The scale of each basis function is calculated independently via a specific SVFG. This includes 0D pixel noise (0DI), 0D energy noise (0DE), 1D blur (1DB), 1D length (1DL) or 2D position (2DP). These models are orthogonal in that they each explore a space in the signal variation domain that cannot be reached by the other basis functions. The variation basis functions, and associated SVFG models are split by output dimensionality, a term loosely used for categorization, and explained further below.

42 ENGINEERING↗
DOE OSTI2020

General approaches for shear-correcting coordinate transformations in Bragg coherent diffraction imaging. Part I

This two-part article series provides a generalized description of the scattering geometry of Bragg coherent diffraction imaging (BCDI) experiments, the shear distortion effects inherent in the 3D image obtained from presently used methods and strategies to mitigate this distortion. Part I starts from fundamental considerations to present the general real-space coordinate transformation required to correct this shear, in a compact operator formulation that easily lends itself to implementation with available software packages. Such a transformation, applied as a final post-processing step following phase retrieval, is crucial for arriving at an undistorted, correctly oriented and physically meaningful image of the 3D crystalline scatterer. As the relevance of BCDI grows in the field of materials characterization, the available sparse literature that addresses the geometric theory of BCDI and the subsequent analysis methods are generalized here. This geometrical aspect, specific to coherent Bragg diffraction and absent in 2D transmission CDI experiments, gains particular importance when it comes to spatially resolved characterization of 3D crystalline materials in a reliable nondestructive manner. This series of articles describes this theory, from the diffraction in Bragg geometry to the corrections needed to obtain a properly rendered digital image of the 3D scatterer. Part I of this series provides the experimental BCDI community with the general form of the 3D real-space distortions in the phase-retrieved object, along with the necessary post-retrieval correction method. Part II builds upon the geometric theory developed in Part I with the formalism to correct the shear distortions directly on an orthogonal grid within the phase-retrieval algorithm itself, allowing more physically realistic constraints to be applied. Taken together, Parts I and II provide the X-ray science community with a set of generalized BCDI shear-correction techniques crucial to the final rendering of a 3D crystalline scatterer and for the development of new BCDI methods and experiments.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Quantitatively accounting for the effects of surface topography on the oxidation kinetics of additive manufactured Hastelloy X processed by electron beam melting

In this work, the effects of surface roughness on the high-temperature corrosion of nickel-based superalloy X produced through electron-beam melting (EBM) additive manufacturing were studied. Surface area of samples in the rough, as-fabricated condition was measured using a 2D cross-section image analysis technique and a 3D image analysis technique. To verify the accuracy of surface area measurements, oxidation testing of samples in the as-fabricated and polished conditions was performed; polished sample oxidation curves were then compared to the as-fabricated sample oxidation curves before and after being adjusted using obtained surface area measurements. It was found that the 2D technique accurately measured surface area and accounted for the overlapping features present on EBM sample surfaces, whereas the 3D technique did not. Further, it was also observed that oxidation kinetics were moderately faster on the alloy X samples in the as-fabricated condition than for the polished condition.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Perspectives of active Si photonics devices for data communication and optical sensing

Si photonics has made rapid progress in research and commercialization in the past two decades. While it started with electronic–photonic integration on Si to overcome the interconnect bottleneck in data communications, Si photonics has now greatly expanded into optical sensing, light detection and ranging (LiDAR), optical computing, and microwave/RF photonics applications. From an applied physics point of view, this perspective discusses novel materials and integration schemes of active Si photonics devices for a broad range of applications in data communications, spectrally extended complementary metal–oxide–semiconductor (CMOS) image sensing, as well as 3D imaging for LiDAR systems. We also present a brief outlook of future synergy between Si photonic integrated circuits and Si CMOS image sensors toward ultrahigh capacity optical I/O, ultrafast imaging systems, and ultrahigh sensitivity lab-on-chip molecular biosensing.

electronic band structure↗