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All sources NASA NTRS DOE OSTI

DOE OSTI2024

In-Process Monitoring and Structural Health Monitoring of Large-Scale Additive Manufacturing Using Acoustic Emission Technique

ORNL collaborated with MISTRAS Group, Inc. to investigate acoustic emission (AE) as a structural health monitoring (SHM) method for large-scale additive manufacturing (AM). Large-scale AM is being adapted as method of producing large structures in a short lead time and cost-effective way. With the growing advancement in AM techniques and application, machine monitoring and part qualification is highly needed. There has been leading research focused on the manufacturing, feedstock material but minimum research on the SHM, defect detection, and nondestructive evaluation (NDE) for AM. Scanning large structure using conventional nondestructive testing (NDT) techniques, such as ultrasound or X-ray, and searching for potential defects can be very time consuming, challenging and cost prohibitive. AE is a passive technique that can be used to monitor and locate defect progression in large structure by distributing group of sensors around the part. This project utilized AE technique and system manufactured/designed by MISTRAS Group to monitor large-scale AM equipment (i.e. Big Area Additive Manufacturing (BAAM) system located at the Oak Ridge National Laboratory – Manufacturing Demonstration Facility (ORNL-MDF) and the printed parts it produces. The AE system provided valuable insight on defect development/progression during and post-printing process.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Aerosol-Jet Printed Sensors for Environmental, Safety, and Health Monitoring: A Review

An emergent direct-write approach, aerosol-jet printing (AJP), is gaining attention for the deployment of rapid and affordable microadditively manufactured energy-efficient sensors and printed electronics. AJP enables a broad range of ink viscosities (0.001–1 Pa s) for printing diverse materials ranging from ceramics and metals to polymers and biological matter. Reproducible, high-spatial-resolution features (≈10 µm), and wide standoff distances (1–11 mm) between the nozzle and the substrate facilitate conformal printing of complex geometrical designs on nonplanar—e.g., stepped or curved—surfaces. Here this paper aims to provide a comprehensive overview of state-of-the-art AJP-based sensors (e.g., strain and temperature gauges, biosensors, photosensors, humidity and surface acoustic wave sensors, dielectric elastomer actuators, and motion, smoke, and hazardous gas detectors) and to discuss prospective applications. The drive toward cost-effective devices that are smaller, lighter, and better-performing remains a frontier challenge in the field of printed electronics. Consequently, as AJP becomes increasingly utilized in the high-volume manufacturing of miniaturized active and passive sensors, it opens a pathway for facile large-scale fabrication of devices for a wide range of consumer and industrial applications, including transportation, agriculture, infrastructure, aerospace, national defense, and healthcare.

3-dimensional↗

DOE OSTI2024

Frequency‐Locked Wireless Multifunctional Surface Acoustic Wave Sensors

Abstract Surface acoustic waves (SAWs) have shown great potential for developing sensors for structural health monitoring (SHM) and lab‐on‐a‐chip (LOC) applications. Existing SAW sensors mainly rely on measuring the frequency shifts of high‐frequency (e.g., >0.1 GHz) resonance peaks. This study presents frequency‐locked wireless multifunctional SAW sensors that enable multiple wireless sensing functions, including strain sensing, temperature measurement, water presence detection, and vibration sensing. These sensors leverage SAW resonators on piezoelectric chips, inductive coupling‐based wireless power transmission, and, particularly, a frequency‐locked wireless sensing mechanism that works at low frequencies (e.g., <0.1 GHz). This mechanism locks the input frequency on the slope of a sensor's reflection spectrum and monitors the reflection signal's amplitude change induced by the changes of sensing parameters. The proof‐of‐concept experiments show that these wireless sensors can operate in a low‐power active mode for on‐demand wireless strain measurement, temperature sensing, and water presence detection. Moreover, these sensors can operate in a power‐free passive mode for vibration sensing, with results that agree well with laser vibrometer measurements. It is anticipated that the designs and mechanisms of the frequency‐locked wireless SAW sensors will inspire researchers to develop future wireless multifunctional sensors for SHM and LOC applications.

Bo, Luyu↗

NASA NTRS1994

An Acoustic Charge Transport Imager for High Definition Television Applications: Reliability Modeling and Parametric Yield Prediction of GaAs Multiple Quantum Well Avalanche Photodiodes

Reliability modeling and parametric yield prediction of GaAs/AlGaAs multiple quantum well (MQW) avalanche photodiodes (APDs), which are of interest as an ultra-low noise image capture mechanism for high definition systems, have been investigated. First, the effect of various doping methods on the reliability of GaAs/AlGaAs multiple quantum well (MQW) avalanche photodiode (APD) structures fabricated by molecular beam epitaxy is investigated. Reliability is examined by accelerated life tests by monitoring dark current and breakdown voltage. Median device lifetime and the activation energy of the degradation mechanism are computed for undoped, doped-barrier, and doped-well APD structures. Lifetimes for each device structure are examined via a statistically designed experiment. Analysis of variance shows that dark-current is affected primarily by device diameter, temperature and stressing time, and breakdown voltage depends on the diameter, stressing time and APD type. It is concluded that the undoped APD has the highest reliability, followed by the doped well and doped barrier devices, respectively. To determine the source of the degradation mechanism for each device structure, failure analysis using the electron-beam induced current method is performed. This analysis reveals some degree of device degradation caused by ionic impurities in the passivation layer, and energy-dispersive spectrometry subsequently verified the presence of ionic sodium as the primary contaminant. However, since all device structures are similarly passivated, sodium contamination alone does not account for the observed variation between the differently doped APDs. This effect is explained by the dopant migration during stressing, which is verified by free carrier concentration measurements using the capacitance-voltage technique.

Hunt, W. D.↗

NASA NTRS2006

Structural Health Monitoring and Impact Detection Using Neural Networks for Damage Characterization

Detection of damage due to foreign object impact is an important factor in the development of new aerospace vehicles. Acoustic waves generated on impact can be detected using a set of piezoelectric transducers, and the location of impact can be determined by triangulation based on the differences in the arrival time of the waves at each of the sensors. These sensors generate electrical signals in response to mechanical motion resulting from the impact as well as from natural vibrations. Due to electrical noise and mechanical vibration, accurately determining these time differentials can be challenging, and even small measurement inaccuracies can lead to significant errors in the computed damage location. Wavelet transforms are used to analyze the signals at multiple levels of detail, allowing the signals resulting from the impact to be isolated from ambient electromechanical noise. Data extracted from these transformed signals are input to an artificial neural network to aid in identifying the moment of impact from the transformed signals. By distinguishing which of the signal components are resultant from the impact and which are characteristic of noise and normal aerodynamic loads, the time differentials as well as the location of damage can be accurately assessed. The combination of wavelet transformations and neural network processing results in an efficient and accurate approach for passive in-flight detection of foreign object damage.

Ross, Richard W.↗

DOE OSTI2021

Humming Trains in Seismology: An Opportune Source for Probing the Shallow Crust

Abstract Seismologists are eagerly seeking new and preferably low-cost ways to map and track changes in the complex structure of the top few kilometers of the crust. By understanding it better, they can build on what is known regarding important, practical issues. These include telling us whether imminent earthquakes and volcanic eruptions are generating telltale underground signs of hazard, about mitigation of induced seismicity such as from deep injection of wastewater, how the Earth and its atmosphere couple, and where accessible natural resources are. Passive seismic imaging usually relies on blind correlations within extended recordings of Earth’s ceaseless “hum” or coda of well-mixed, small vibrations. In this article, we propose a complementary approach. It is seismic interferometry using opportune sources—specifically ones not stationary in time and moving in a well-understood configuration. Its interpretation relies on an accurate understanding of how these sources radiate seismic waves, precise timing, careful placement of pairs of listening stations, and seismic phase differentiation (surface and body waves). Massive freight trains were only recently recognized as such a persistent, powerful cultural (human activity-caused) seismic source. One train passage may generate a tremor with an energy output of a magnitude 1 earthquake and be detectable for up to 100 km from the track. We discuss the source mechanisms of train tremors and review the basic theory on sources. Finally, we present case studies of body- and surface-wave retrieval as an aid to mineral exploration in Canada and to monitoring of a southern California fault zone. We believe noise recovery from this new signal source, together with dense data acquisition technologies such as nodes or distributed acoustic sensing, will deeply transform our ability to monitor activity in the shallow crust at sharpened resolution in time and space.

Geochemistry & Geophysics↗

DOE OSTI2020

Static Strain Modelling, Calibration, and Measurements for High-Temperature Wireless SAW Resonator Operation

Static strain measurements are relevant for Integrated System Health Monitoring of civil structures, aircrafts, power plants and advanced manufacturing equipment, with implications for safety, process efficiency, and maintenance costs. Wireless strain sensing is highly desirable where the presence of wires poses significant safety concerns, increases maintenance, and thus overall costs, or where they are not feasible, such as in applications which contain moving parts. This paper presents wireless interrogation of surface acoustic wave resonators (SAWRs) fabricated on langasite (LGS) along Euler angles (0°, 138.5°, 32.9°) and aimed at the detection of static strain at hightemperature (HT, above 100°C). Both commercial HT strain gauges and finite element analysis (FEA Abaqus software) were used and compared for SAWR strain calibration from room temperature (RT) to HT. In addition, this work investigated a compromise between high temperature operation vs. sensitivity based on the thickness of ceramic adhesive used. For instance, a reduction in the adhesive thickness from about 150 μm to 135 μm, resulted in a 39% increase in sensitivity at RT. It was also observed that the sensitivity dropped up to 34% from RT to 200°C. Furthermore, wireless operation, calibration, and increase in sensitivity constitute important advances in the use of LGS SAW devices to monitor static stress in high-temperature harsh environments.

42 ENGINEERING↗

DOE OSTI2021

A surface acoustic wave hydrogen sensor with tin doped indium oxide layers for intermediate temperatures

We report high temperature surface acoustic wave (SAW) gas sensors with conducting sensing layers require tuning of the sheet conductivity for optimal response. Conducting metal oxides are attractive sensing materials for their tunable electronic properties and high thermal stability, amongst others. Here, we have investigated the application of indium oxide (IO) and indium tin oxide (ITO) films on langasite (LGS)-based SAW reflective delay line sensor devices for monitoring hydrogen at 350 °C. Specifically, we modeled the effect of the IO and ITO sensing layer thickness on the wave velocity, attenuation, and effective electromechanical coefficient. This was followed by an experimental demonstration of tuning of the ITO film sheet conductivity by controlling the dopant concentration and yielding an improvement in the sensor sensitivity. The current study provides a pathway towards the development of conductivity-based sensing layers for high temperature SAW gas sensors with improved sensitivity.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRSDate not supplied

TPSAS-NF1676L-11435-DND

Acoustical studies of atmospheric events like convective storms, shear-induced turbulence, acoustic gravity waves, microbursts, hurricanes, and clear air turbulence (CAT) over the past thirty years have established that these events are strong emitters of infrasound. Several mechanisms for the production of infrasound have been proposed, for example by the acceleration of vorticity or by space-time correlations of the turbulent Reynolds stresses (Lighthill theory). Electromagnetic (EM) sensors suffer two severe disadvantages in the detection of clear air turbulence and severe storms. The first is the inability to receive returns in clear air, where reflective targets (precipitation, particulate matter) are absent. The second disadvantage is that EM systems, being active, require scanning to locate an event, as opposed to a passive infrasonic array, which receives infrasonic radiation independently of event location. Further, EM systems, even weather radar ("NEXRAD"), do not have the extensive range (hundreds of miles) characteristic of infrasound. The leading laboratory for studies on atmospheric infrasound over the past thirty years has been the Environmental Technology Laboratory of the National Oceanic and Atmospheric Administration. This laboratory conducted measurements of infrasound from many sources, among which clear air turbulence was but a small part of the overall program. The summary of the results of this program suggests for development of a practical detection system. In other words, despite the progress made in this area, there does not exist today a National network of stations to monitor infrasound from turbulence. Under Innovative Partnership Program, Researchers at NASA Langley Research Center have been working to achieve that goal. As a first step, NASA Langley has designed and developed a portable infrasonic detection system which can be used to make useful infrasound measurements at a location where it was not possible previously. The design and results of the compact system, based upon laboratory and field experiments, will be presented.

Qamar Shams↗

DOE OSTI2024

DAISY Benchmark Performance Data

This repository contains the underlying data from benchmark experiments for Drifting Acoustic Instrumentation SYstems (DAISYs) in waves and currents described in "Performance of a Drifting Acoustic Instrumentation SYstem (DAISY) for Characterizing Radiated Noise from Marine Energy Converters" (https://link.springer.com/article/10.1007/s40722-024-00358-6). DAISYs consist of a surface expression connected to a hydrophone recording package by a tether. Both elements are instrumented to provide metadata (e.g., position, orientation, and depth). Information about how to build DAISYs is available at https://www.pmec.us/research-projects/daisy. The repository's primary content is three compressed archives (.zip format), each containing multiple MATLAB binary data files (.mat format). A table relating individual data files to figures in the paper, as well as the structure of each file, is included in the repository as a Word document (Data Description MHK-DR.docx). Most of the files contain time series information for a single DAISY deployment (file naming convention: [site]_DAISY_[Drift #].mat) consisting of processed hydrophone data and associated metadata. For a limited number of DAISY deployments, the hydrophone package was replaced with an acoustic Doppler velocimeter (file naming convention: [site]_DAISY_[Drift #]_ADV.mat). Data were collected over several years at three locations: (1) Sequim Bay at Pacific Northwest National Laboratory's Marine & Coastal Research Laboratory (MCRL) in Sequim, WA, the energetic tidal channel in Admiralty Inlet, WA (Admiralty Inlet), and the U.S. Navy's Wave Energy Test Site (WETS) in Kaneohe, HI. Brief descriptions of data files at each location follow. - MCRL - (1) Drift #4 and #16 contrast the performance of a DAISY and a reference hydrophone (icListen HF Reson), respectively, in the quiescent interior of Sequim Bay (September 2020). (2) Drift #152 and #153 are velocity measurements for a drifting acoustic Doppler velocimeter in in the tidally-energetic entrance channel inside a flow shield and exposed to the flow, respectively (January 2018). (3) Two non-standard files are also included: DAISY_data.mat corresponds to a subset of a DAISY drift over an Adaptable Monitoring Package (AMP) and AMP_data.mat corresponds to approximately co-temporal data for a stationary hydrophone on the AMP (February 2019). - Admiralty Inlet - (1) Drift #1-12 correspond to tests with flow shielded DAISYs, unshielded DAISYs, a reference hydrophone, and drifting acoustic Doppler velocimeter with 5, 10, and 15 m tether lengths between surface expression and hydrophone recording package (July 2022). (2) Drift #13-20 correspond to tests of flow shielded DAISYs with three different tether materials (rubber cord, nylon line, and faired nylon line) in lengths of 5, 10, and 15 m (July 2022). - WETS - (1) Drift #30-32 correspond to tests with a heave plate incorporated into the tether (standard configuration for wave sites), rubber cord only, and rubber cord, but with a flow shielded hydrophone (November 2022). (2) Drift #49-58 and Drift #65-68 correspond to measurements around mooring infrastructure at the 60 m berth where time-delay-of-arrival localization was demonstrated for different DAISY arrangements and hydrophone depths (November 2022).

16 TIDAL AND WAVE POWER↗

NASA NTRS2021

Large-scale space use of large juvenile and adult smalltooth sawfish Pristis pectinata: implications for management

The smalltooth sawfish Pristis pectinata is an endangered species endemic to the Atlantic Ocean. The only known viable populations occur in the USA along both coasts of Florida and in the western Bahamas. Little is known about habitat use and movement ecology of large juvenile and adult smalltooth sawfish. Although Critical Habitat — a management designation in the USA — has been identified for small juveniles, it has yet to be identified for these life stages. Between May 2016 and April 2019, we used passive acoustic telemetry and 3 large data sharing networks of receivers to track movements of 43 large juvenile and adult smalltooth sawfish. During this study, 24 females and 19 males were implanted with transmitters with estimated 4 or 10 yr battery lives. These tagged individuals were detected off the southeastern USA on 461 receivers ranging from off the coast of Brunswick, Georgia, to the lower Florida Keys, and along the Gulf coast to Apalachee Bay, Florida. Seasonal migrations were undertaken by 58% (43% mature; 57% immature) of the tagged individuals, with the remainder being apparent residents of their tagging locations. Tagged sawfish from both size classes and of both sexes migrated, which indicates that neither sex nor length is a predictor of whether a sawfish will migrate or not. Although both coasts of Florida were used for migration, most individuals consistently used the same coast when they migrated. The areas surrounding Boca Grande, Cape Canaveral, and the lower Florida Keys were heavily visited sites that could be further evaluated as potential Critical Habitat for these life stages. Understanding the movement patterns of this Critically Endangered species is essential for creating policies to protect areas important for promoting growth of the population.

Pristis pectinata Habitat use · Acoustic monitorin↗