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DOE OSTI2025

Quantification of Changes in Fill Tube Curvature During Target Assembly

National Ignition Facility (NIF) targets used for inertial confinement fusion (ICF) experiments are precision-engineered assemblies composed of more than 100 components carefully and precisely assembled with accuracies no larger than a few micrometers in most cases. When individual components deviate from these strict specifications during the assembly process, they can induce target failure. An integral component essential to ICF targets is the capsule-fill-tube assembly. This assembly involves bonding the capsule to a fused silica tube less than 5 μm in thickness, through which the tritium and deuterium (T 2 + D 2 ) fuel mixture is injected into the capsule prior to the NIF shot. The filling tube is bonded to a larger fused silica capillary, about 130 μm in outer diameter, which is coated with a polymeric layer on the order of a 10-μm thickness or less. Only tubes exhibiting a deflection equivalent to less than 1% of their total length from a perfectly straight line are suitable for assembly. Slight curvatures on the order of 1 mm over 10 cm can induce unwanted stresses, potentially causing capsule misalignment and resulting in clogging or leaks during the filling process. Despite manually qualitatively sorting each tube for straightness prior assembly, it has been found that the treatments the tubes undergo once attached to the capsule can alter their curvature. Filling tubes that initially satisfy straightness tolerances can undergo geometric deformation, resulting in curvature deviations exceeding 1% of their total length and thus failing to meet target assembly requirements. Here, in this study, we propose a metric to assess the degree of curvature of the filling tubes and to gauge their changes in curvature caused by the standard thermal processing methods employed in target assembly. In addition, we suggest alternatives to mitigate tube curvature, ensuring they conform to specifications following assembly in the final targets.

Materials science↗

DOE OSTI2020

Experimental Investigation of Polymer Induced Fouling of Heater Tubes in the First-ever Polymer Flood Pilot on Alaska North Slope

Polymer flooding has been validated in the lab and by successful applications in other countries, such as Canada and China, to be an effective EOR technique for heavy oil reservoirs. Currently, polymer flooding is being pilot tested for the first time in the Schrader Bluff viscous oil reservoir at Milne Point field on Alaska North Slope (ANS). One of the major concerns of the operator is the impact of polymer on the oil production system after polymer breakthrough, especially the polymer induced fouling issues in the heat exchanger. This study investigates the propensity of polymer fouling on the heater tubes as a function of different variables, with the ultimate goal of determining safe and efficient operating conditions. A unique experimental set-up was indigenously designed and developed to simulate the fouling process on the heating tube. The influence of heating tube skin temperature, tube material, and polymer concentration on fouling tendency was investigated. Under each test condition, the test was run five times with the same tube, and in each run, the freshly prepared synthetic brine and polymer solution were heated from 77°F to 122°F to mimic field operating conditions. The heating time and fouling amount were recorded for each run. The morphology and composition of the deposit samples were analyzed by environmental scanning electron microscopy (ESEM) and X-ray diffraction (XRD), respectively. It has been found that, in general, the presence of polymer in produced fluids would aggravate the fouling issues on both carbon steel and stainless steel surfaces at all tested skin temperatures (165°F, 250 °F and 350°F), but only higher skin temperatures of 250°F and 350°F could cause polymer induced fouling issues on the copper tube surface and the fouling tendency increased with polymer concentration. At the lower skin temperatures of 165°F, no polymer-induced fouling was identified on the copper tube. A critical temperature that is related to the cloud point of the polymer solution was believed to exist, below which polymer induced fouling would not occur and only mineral scale deposited, but above which the polymer would obviously aggravate the fouling issue. The heating efficiency of the tube would be reduced gradually as more fouling material accumulates on its surface. The ESEM results indicate that if polymer precipitated and deposited on the surface, it would bond to the mineral crystals to form a stronger three- dimensional network structure, and that is why the polymer induced fouling was tougher and more difficult to be removed from the tube surface. The XRD analysis results confirm that the presence of polymer in the fluids can enhance the mineral scale propensity. Overall, the study results have provided practical guidance to the field operator for the ongoing polymer flooding pilot test on ANS. This study may also prove to be valuable for other chemical EOR projects around the world.

Alaska North Slope↗

NASA NTRS1985

Propagation of nonlinear, radiatively damped longitudinal waves along magnetic flux tubes in the solar atmosphere

For solar magnetic flux tubes three types of waves are compared: longitudinal MHD tube waves, acoustic tube waves propagating in the same tube geometry but with rigid walls and ordinary acoustic waves in plane geometry. It is found that the effect of the distensibility of the tube is small and that longitudinal waves are essentially acoustic tube waves. Due to the tube geometry there is considerable difference between longitudinal waves or acoustic tube waves and ordinary acoustic waves. Longitudinal waves as well as acoustic tube waves show a smaller amplitude growth, larger shock formation heights, smaller mean chromospheric temperature but a steeper dependence of the temperature gradient on wave period.

Herbold, G.↗

NASA NTRS1986

The equilibrium structure of thin magnetic flux tubes. II

The thermal structure of the medium inside thin, vertical magnetic flux tubes embedded in a given external atmosphere is investigated, assuming cylindrical symmetry and a depth-independent plasma beta. The variation with tube radius of the temperature on the tube axis is computed and the temperature on the tube wall is estimated. The temperature variation across the flux tube is found to be due to the depth variation of the intensity and to the density stratification of the atmosphere. Since the temperature difference between the axis and the wall is small in thin flux tubes (of the order of 10 percent), the horizontal temperature gradient may often be neglected and the temperature in a tube of given radius may be described by a single function of depth. Thus, a more detailed numerical treatment of the radiative transfer within thin flux tubes can be substantially simplified by neglecting horizontal temperature differences within the flux tube proper.

Kalkofen, W.↗

NASA NTRS1990

Design of a telescoping tube system for access and handling equipment

Spacecraft processing presents unique problems for the design of ground support equipment. A telescoping tube system consists of a number of nested structural tubes that can be extended and retracted (telescoped) while supporting a load. A typical telescoping tube system provides lateral, torsional, and vertical support for an access platform. Several concepts for improved telescoping tubes were developed with emphasis placed on reliability, ease of maintenance, and cost effectiveness. The most promising prototype design utilizes adjustable rollers running on tracks bolted to the tube sections. A wire rope deployment system ensures that all tube sections are controlled during extension and retraction. Track shimming and roller adjustment allow for fabrication of a high precision tube assembly that does not require extensive machining or unusually large shop equipment. The use of rolling contact eliminates the contamination problems encountered with sliding tubes in previous designs. The prototype design is suitable for indoor or outdoor use. A prototype tube assembly was fabricated and tested for strength, stiffness, maintainability, and endurance.

Littlefield, Alan C.↗

NASA NTRS1937

Torsion Tests of Tubes

This report presents the results of tests of 63 chromium-molybdenum steel tubes and 102 17st aluminum-alloy tubes of various sizes and lengths made to study the dependence of the torsional strength on both the dimensions of the tube and the physical properties of the tube material. Three types of failure are found to be important for sizes of tubes frequently used in aircraft construction: (1) failure by plastic shear, in which the tube material reached its yield strength before the critical torque was reached; (2) failure by elastic two-lobe buckling, which depended only on the elastic properties of the tube material and the dimensions of the tube; and (3) failure by a combination of (1) and (2) that is, by buckling taking place after some yielding of the tube material.

Stang, Ambrose H↗

NASA NTRS1993

Characterization of the microstructure of Nb-1wt.%Zr-0.1wt.%C tubes as affected by thermomechanical processing

Microstructure of Nb-1Zr-0.1C tubes were characterized as affected by extrusion temperature of the tube shell and its thermomechanical processing to tubing. Two tube shells of about 40-mm outside diameter (OD) and 25-mm inside diameter (ID) were extruded 8:1 from a vacuum arc-melted ingot at 1900 and 1550 K. Two different OD tubes of approximately 0.36-mm wall thickness were fabricated from each tube shell by a series of 26 cold drawing operations with two in process anneals. The microstructure of tube shells and the tubing before and after a 2-step heat treatment were characterized. Residue extracted chemically from each sample was also analyzed to identify the precipitates. The results concerning the effect of the initial extrusion temperature and subsequent processing on the microstructure of the tubes are presented together with a review of results from similar work on Nb-1Zr-0.1C sheet stock.

Uz, Mehmet↗

NASA NTRS1994

Equilibrium structure of solar magnetic flux tubes: Energy transport with multistream radiative transfer

We examine the equilibrium structure of vertical intense magnetic flux tubes on the Sun. Assuming cylindrical geometry, we solve the magnetohydrostatic equations in the thin flux-tube approximation, allowing for energy transport by radiation and convection. The radiative transfer equation is solved in the six-stream approximation, assuming gray opacity and local thermodynamic equilibrium. This constitutes a significant improvement over a previous study, in which the transfer was solved using the multidimensional generalization of the Eddington approximation. Convection in the flux tube is treated using mixing-length theory, with an additional parameter alpha, characterizing the suppression of convective energy transport in the tube by the strong magnetic field. The equations are solved using the method of partial linearization. We present results for tubes with different values of the magnetic field strength and radius at a fixed depth in the atmosphere. In general, we find that, at equal geometric heights, the temperature on the tube axis, compared to the ambient medium, is higher in the photosphere and lower in the convection zone, with the difference becoming larger for thicker tubes. At equal optical depths the tubes are generally hotter than their surroundings. The results are comparatively insensitive to alpha but depend upon whether radiative and convective energy transport operate simultaneously or in separate layers. A comparison of our results with semiempirical models shows that the temperature and intensity contrast are in broad agreement. However, the field strengths of the flux-tube models are somewhat lower than the values inferred from observations.

Hasan, S. S.↗

NASA NTRS1997

Response of the water status of soybean to changes in soil water potentials controlled by the water pressure in microporous tubes

Water transport through a microporous tube-soil-plant system was investigated by measuring the response of soil and plant water status to step change reductions in the water pressure within the tubes. Soybeans were germinated and grown in a porous ceramic 'soil' at a porous tube water pressure of -0.5 kpa for 28 d. During this time, the soil matric potential was nearly in equilibrium with tube water pressure. Water pressure in the porous tubes was then reduced to either -1.0, -1.5 or -2.0 kPa. Sap flow rates, leaf conductance and soil, root and leaf water potentials were measured before and after this change. A reduction in porous tube water pressure from -0.5 to -1.0 or -1.5 kPa did not result in any significant change in soil or plant water status. A reduction in porous tube water pressure to -2.0 kPa resulted in significant reductions in sap flow, leaf conductance, and soil, root and leaf water potentials. Hydraulic conductance, calculated as the transpiration rate/delta psi between two points in the water transport pathway, was used to analyse water transport through the tube-soil-plant continuum. At porous tube water pressures of -0.5 to-1.5 kPa soil moisture was readily available and hydraulic conductance of the plant limited water transport. At -2.0 kPa, hydraulic conductance of the bulk soil was the dominant factor in water movement.

NASA Center JSC↗

NASA NTRS1994

Detection of Cracks at Welds in Steel Tubing Using Flux Focusing Electromagnetic Probe

The inspection of weldments in critical pressure vessel joints is a major concern in the nuclear power industry. Corrosive environments can speed the fatigue process and access to the critical area is often limited. Eddy current techniques have begun to be used to help overcome these obstacles [1]. As direct contact and couplants are not required, remote areas can be inspected by simply snaking an eddy current coil into the intake tube of the vessel. The drawback of the eddy current method has been the high sensitivity to small changes in the conductivity and permeability of the test piece which are known to vary at weldments [1]. The flaw detection mechanism of the flux focusing electromagnetic probe can help alleviate these difficulties and provide a unique capability for detecting longitudinal fatigue cracks in critical tube structures. The Flux Focusing Electromagnetic Flaw Detector, originally invented for the detection of fatigue and corrosion damage in aluminum plates [2-3], has been adapted for use in testing steel tubing for longitudinal fatigue cracks. The modified design allows for the probe to be placed axisymmetrically into the tubing, inducing eddy currents in the tube wall. The pickup coil of the probe is fixed slightly below the primary windings and is rotated 90 so that its axis is normal to the tube wall. The magnetic flux of the primary coil is focused through the use of ferromagnetic material so that in the absence of fatigue damage there will be no flux linkage with the pickup coil. The presence of a longitudinal fatigue crack will cause the eddy currents induced in the tube wall to flow around the flaw and directly under the pickup coil. The magnetic field associated with these currents will then link the pickup coil and an unambiguous increase in the output voltage of the probe will be measured. The use of the flux focusing electromagnetic probe is especially suited for the detection of flaws originating at or near tube welds. The probe is shown to discriminate against signals due solely to the weld joint so that flaw signals are not hidden in the background in these locations. Experimental and finite element modeling results are presented for the flaw detection capabilities of the probe in stainless steel tubes.

Wincheski, Buzz↗

NASA NTRSDate not supplied

Using X-Ray Computed Tomography to Image Apollo Drive Tube 73002

The Apollo missions collected 382 kg of rock, regolith, and core samples from six locations on the nearside of the Moon. Today, just over 84% by mass of the Apollo collection remains in pristine condition within the curation facility at Johnson Space Center. Most Apollo samples have been well characterized, however there are several types of samples that have remained wholly or largely unstudied since their return, and/or that have been curated under special conditions. These sample types are: (1) unopened samples sealed under vacuum on the Moon; (2) unopened (but unsealed) drive tubes; (3) Apollo 17 samples frozen shortly after their return; and (4) Apollo 15 samples opened and stored in a helium atmosphere since their return. NASA solicited proposals for the Apollo Next Generation Sample Analysis Program (ANGSA), and 9 teams were selected to study: (1) unsealed, unopened drive tube 73002; (2) sealed, unopened drive tube 73001 (paired with 73002); and (3) a subset of the frozen and He-purged samples [1]. The first sample opened as part of the ANGSA program was drive tube 73002. This was originally a ~30 cm long, 4 cm diameter drive tube collected on a landslide deposit near Lara Crater at the Apollo 17 landing site. It was part of a ~60 cm long double drive tube collected, and the bottom half of the tube (73001) was sealed under vacuum on the Moon [2]. Prior to opening sample 73002, the sample was imaged with a high resolution X-ray Computed Tomography (XCT) scan of the entire tube. Additional XCT scans have been made of “large” clasts removed from the core as part of the dissection process [3]. Here we present the whole tube and close-up XCT data from 73002, and talk about the utility of the scans as part of the curation process, including the potential for future science returns from the high resolutions scans.

R A Zeigler↗

DOE OSTI2025

Toward Verification of RANS Simulations of the T-Tube Modular Divertor Using Large Eddy Simulations of Impinging Turbulent Plane Jets

Turbulent impinging jets have been proposed to cool high heat flux plasma-facing components such as the solid tungsten target plates of the divertor in long-pulse magnetic fusion energy reactors. In particular, the T-tube modular divertor, originally developed by the ARIES Team, consists of two concentric cylindrical tubes where helium flows through a slot in the inner tube, forming an approximately planar jet that impinges upon and cools the inner surface of the pressure boundary (namely, the outer tube) and the ~15-cm 2 plasma-facing W target. The objective of this work is to demonstrate that large eddy simulations (LESs) accurately simulate the thermal transport in canonical flows that comprise the cooling flow in the T-tube, as well as validate temperatures from LES with experimental measurements in a simplified T-tube geometry. Wall‑resolved LESs, validated by experimental data and verified by direct numerical simulations (DNSs), provide benchmark data for two canonical flows in the T‑tube, namely, planar impinging and wall jets, for Reynolds numbers Re B = 4 × 10 3 to 2 × 10 4 . Our LES results are within 4% to 12% root-mean-square error (RMSE) of surface Nusselt number distributions (Nu) from experiments and DNSs. The validated LES results are then used as the ground truth to evaluate four Reynolds‑averaged Navier-Stokes (RANS) turbulence closures, namely, the k‑ω SST, realizable k‑ε, GEKO, and γ‑SST models. The k‑ω SST model has the best overall performance in terms of heat transfer, giving surface Nu within 12% RMSE of the LES results for high‑ReB impinging jets and reduced overprediction in the wall‑jet region. The GEKO model with default constants has the next best performance, providing slightly better Nu predictions for low ReB impinging jets (versus k-ω SST) but worse overall performance over the full range of ReB studied here. The realizable k‑ε turbulence model significantly overestimates turbulence near the stagnation point, while the γ‑SST model suppresses near‑wall production, biasing the simulations toward simulating laminar surface heat transfer. Simulations of the simplified T‑tube show that LES and RANS simulations with the k‑ω SST model give nearly identical average heat transfer coefficients (HTCs) over the impingement surface. The realizable k‑ε model predicts significantly lower wall temperatures due to overestimation of HTC in the outlet flow.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2024

Flow and Heat Transfer Experimental Study for 3D-Printed Solar Receiving Tubes With Helical Fins at Internal Surface

3D-printing technology was applied to fabricate novel solar thermal collection tubes that have internal heat transfer enhancement fins and external surfaces with high solar absorptivity and low emissivity due to the ability to use different materials in one tube. Helical fins were selected to introduce circumferential flow and thus minimize the circumferential temperature difference of the tube that receives sunlight on one side. The structures of the helical fins were previously optimized from computational fluid dynamics (CFD) analysis with the objective of low entropy production rate by looking for high heat transfer coefficient and relatively lower pressure loss. High-temperature alloy, Inconel-718, was used to 3D print the tubes, which can resist corrosion for the potential application of molten chloride salts as heat transfer fluid. Experimental tests were carried out using water as the heat transfer fluid with the high heat flux provided by a tubular furnace heater. The tested Reynolds number ranges from 3.9 × 10 3 to 6.1 × 10 4 . Heat transfer coefficients of up to 2.8 times that of the smooth tube could be obtained with the expense of increased pressure loss compared to that of the smooth tube. The total system entropy generation can be significantly reduced due to the benefit of heat transfer enhancement that is greater than the expenses of the increased pressure loss. The experimental results of the 3D-printed heat transfer tubes confirmed the CFD-based results of fin optimization. Furthermore, the novel heat transfer tube is recommended for application in concentrating solar power systems.

14 SOLAR ENERGY↗

DOE OSTI2023

The deformation and burst behavior of Zircaloy-4 cladding tubes with hydride rim features subject to internal pressure loads

This study is motivated by the desire to conduct a separate effects test replicating specific aspects of an in-pile pulse reactor test on high exposure light water reactor (LWR) fuel rods. The principal purpose of the tests was to determine whether temperature and or hydrogen concentration thresholds exist in assessing the vulnerability of a stress relieved zirconium alloy cladding tubes to low strain ruptures. A secondary objective was to determine whether observations of the cladding stress during deformation could aid in the understanding of the crack formation and propagation in cladding tubes with hydride rim features. Here, the study utilized artificially hydrided Zircaloy-4 cladding tubes and an isothermal, internal pressure test that was controlled with an in-situ strain measurement. The test results show a clear transition in failure vulnerability between room temperature and 150 °C. Below 150 °C, cladding tubes rupture at very low uniform plastic strain—even at relatively modest cladding hydrogen levels. At and above 150 °C, cladding tubes only rupture at low uniform plastic strain if the cladding hydrogen content is greater than 500 ppm and usually experience at least some modest amount of plastic deformation prior to rupture. Post-test metallographs from non-ruptured cladding tubes show numerous primary cracks forming in the hydride rim and arresting at the metal/hydride interface. This observation combined with the decrease in bulk yielding of hydrided cladding tubes when compared to fresh non-hydrided tubes leads to the conclusion that the fracture stress of the hydride rims is related to and bounded by the yield stress of the zirconium metal. Some evidence is presented for a change in crack propagation mechanism from one of void formation on hydride plates and linkage at temperatures below 150 °C to more classical ductile shearing beneath the primary crack tip at temperatures above 150 °C. This apparent change in crack propagation mechanism may help explain the observed temperature and hydrogen concentration thresholds.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2020

A new flow pattern map for flow boiling of R410A in horizontal micro-fin tubes considering the effect of the helix angle

This paper presents an improved flow pattern map for flow boiling in horizontal micro-fin tubes considering the effect of helix angle. The proposed map is modified from the one developed for horizontal smooth tubes by Wojtan et al. (2005) and takes the early transition to annular flow due to micro-fin geometry into account. Visualization of R410A flow boiling is carried out through the transparent smooth and micro-fin tubes with 0°, 10° and 18° helix angle and plotted on the proposed map for comparison. The result shows that the flow pattern map for micro-fin tube with 0° helix angle is generally similar to that for the smooth tube. For the tube with 10° and 18° helix angle, the annular flow occurs at lower vapor quality and lower mass flux. The proposed map shows good agreements when compared with the visualization and reflects the downward shift (to lower mass flux and vapor quality conditions) of the SW-WA transition with the increase of the helix angle. In order to further validate the proposed model, the flow pattern transitions calculated from the equations are also compared with the experimental data of the micro-fin tube in literature. The results show that the modified map increase the prediction accuracy of the flow patterns in the micro-fin tube.

42 ENGINEERING↗

DOE OSTI2020

Cross-code comparison of the impact of the fill tube on high yield implosions on the National Ignition Facility

Fill tubes are used to inject deuterium and tritium fuel into inertial confinement fusion capsules fielded on the National Ignition Facility. These fill tubes have been shown to have a detrimental effect on capsule performance, primarily by introducing a low-density pathway into the central fuel region that enables the jetting of ablation material into the hot spot. Due to the complexity of the highly nonlinear flow associated with the fill tube and the challenge of diagnosing the evolution of the fill tube jet late in the implosion experiments, the uncertainty in how this perturbation source evolves is great. In this work, we report on the results of a detailed code comparison performed to understand uncertainties in computational modeling of the impact of fill tubes on implosion performance. The study employed two radiation-hydrodynamics codes, HYDRA and xRAGE, which employ very different meshing strategies and hydrodynamics solvers, as well as two radiation transport methodologies, discrete ordinates and multi-group diffusion. Our results demonstrate generally good agreement between codes through most of the implosion although they indicate sensitivity to opacity averaging methods. Late in the implosion, differences arise in the distribution and amount of contaminant although these differences have a remarkably small impact on the amount of yield reduction due to the fill tube. While these results demonstrate sensitivity in fill tube modeling to algorithmic choices, the observed differences between codes are small relative to known sensitivities due to expected variations in the fill tube geometry. Finally, we have developed a methodology for performing multi-group diffusion simulations that show good agreement with the more accurate discrete ordinates method

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2020

Thermal shock resistance of multilayer silicon carbide receiver tubes for 800°C molten salt concentrating solar power application

CSP power tower receiver systems during rapid transient weather periods can be vulnerable to thermal shock conditions from rain that which can facilitate the onset of leaks and failures that can have catastrophic consequences. Silicon carbide (SiC) materials have attractive receiver application characteristics for being light weight, having high-strength and excellent thermal shock resistance performance which make them a particularly good fit for receiver absorber materials in CSP. In this investigation, the performance characteristics of Ceramic Tubular Products (CTP) SiC ceramic matrix composite (CMC), multilayered tubes were explored with respect to thermal shock performance for solar receiver applications in next generation CSP plants. Here, thermal shock testing was performed at the Sandia National Laboratories (SNL) Solar Furnace facility using a dynamic stage and thermal shock tube test setup. The tubes tested under incident solar heat flux of 100 W/cm2 were heated with inner tube temperatures reaching approximately 800 °C, with outer temperatures exceeding or just reaching 1000 El for the multilayer and monolithic SiC tubes respectively. The tubes were then quenched with simulated rain. The tubes were then cooled and subjected to hoop stress analysis using an Instron device to assess their subsequent mechanical strength. Furthermore, the on-sun study experimental results indicate an average of 24.2% and 97% higher hoop strength for the CMC tubes than those composed of monolithic SiC and aluminum oxide (A1203) respectively.

14 SOLAR ENERGY↗

DOE OSTI2023

A Lizard-inspired Tube Inspector (LTI) Robot

This final report summarizes the research findings of the current project. This project is a collaboration between New Mexico State University (NMSU) as a lead (Recipient) and Arizona State University (ASU) as a Co-Recipient. Tubular structures are common components of boilers and heat exchangers in power plants. Over time, these components may suffer corrosion, cracks, and stress-corrosion cracks in either the body or the welded connections. A single tube leakage can cause an outage of several weeks. Regular inspection is a key safety factor when ensuring that power plants are maintained in reliable, operational condition. This inspection, however, is challenging, time-consuming, and in many cases impossible due to accessibility issues and safety concerns. Recent developments in robotic-based inspection can offer a great solution. Hard-to-reach places can be inspected without overhauling the unit, saving time and cost. Although several robots have been designed and implemented successfully for inspecting power plant components, in particular tubular structures, their mobility and flexibility are limited. Most of these robots use wheels for mobility which reduces their maneuverability of these robots. Moreover, they usually use magnets to attach to tubes which will not work on tubes with non-ferromagnetic materials. These robots usually carry measurement tools for a particular non-destructive testing (NDT) method such as ultrasound testing (UT) that requires a couplant to perform a point-by-point (scanning) inspection of the tubular structure. In this project, we developed a versatile lizard-inspired tube inspector (LTI) robot with embedded inspection sensing components for tube inspection which removes the need for point-by-point scanning of tube surface for crack and corrosion detection. Inspired by a “lizard”, the novelty of the current project is the integration of couplant-free ultrasound sensing and transmission, advanced data-driven defect detection and imaging, and friction-based mechanical mobility components in a single robot to eliminate a need for smooth surfaces and simple geometry for mobility and scanning. The LTI robot could replace the wheel-based approach with friction-based mobility to significantly increase the flexibility and maneuverability of the robot. The LTI robot can get into a power plant unit, such as a boiler, from a small area allowing it to access a component of interest for inspection (e.g., move on OD, curved and flat surfaces, non-ferromagnetic or ferromagnetic materials, and tubes with rough surfaces and complex geometries). Additionally, an advanced data-driven method using ultrasound data was pioneered to allow the robot to detect defects in the entire area between the robot’s multi-functional mobility system (grippers). Integrating a couplant-free ultrasound sensing in the robot’s grippers as well as using advanced data-driven methods allowed the LTI to detect defects in the entire cross-section of a tube using its grippers when stationary and when mobile.

20 FOSSIL-FUELED POWER PLANTS↗