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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 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Hierarchical microstructure of Yb-filled skutterudites through ultrasonically atomized spherical powders for enhanced thermoelectric performance

Hierarchical microstructures are widely explored as a strategy to reduce lattice thermal conductivity in thermoelectric materials while preserving favorable electronic transport. Here we demonstrate that ultrasonic atomization of precursor powders provides an intrinsic pathway to generate such architectures in n-type Yb0.3Co4Sb12 skutterudites. Materials were synthesized by both conventional sealed-ampoule and ultrasonic atomization routes, each yielding essentially single-phase skutterudite after densification. However, the atomized spherical powders undergo a distinct reaction-driven microstructural evolution during thermal treatment prior to densification. Electron microscopy reveals that the skutterudite phase within the particles induces swelling, cracking, and fragmentation of the droplets before consolidation. Multimodal structural and microstructural characterizations show that densification of these fragmented powders produces a hierarchical microstructure consisting of submicron grains, micrometer-scale faceted crystallites, and powder-derived domains separated by oxide-decorated boundaries. Comprehensive thermoelectric transport measurements evidence that this multiscale architecture lowers the lattice thermal conductivity while maintaining favorable electronic transport, leading to an average ~10% enhancement in the thermoelectric figure of merit. Complementary 121Sb Mössbauer spectroscopy further indicates lattice softening in the atomized material. These results demonstrate that ultrasonic atomization provides an effective route to engineer hierarchical microstructures in skutterudite thermoelectrics and offers a promising strategy for tailoring thermal transport in energy-conversion materials.

Bouteiller, Hugo [ORNL] (ORCID:0009000421322962)↗
DOE OSTI2020

Determination of acoustic nonlinearity parameters using thermal modulation of ultrasonic waves

This study presents a test method and its theoretical framework to determine the acoustic nonlinearity parameters (α, β, δ) of material using thermal modulation of ultrasonic waves. Temperature change-induced thermal strain excites the nonlinear response of the material and modulates the ultrasonic wave propagating in it. Experimental results showed a strong correlation between the relative wave velocity change and the temperature change. With a quadratic polynomial model, the acoustic nonlinearity parameters were obtained from the polynomial coefficients by curve fitting the experimental data. Their effects on thermal-induced velocity change were discussed. The parameters α, β, and δ govern the hysteretic gap, average slope, and curvature of the correlation curve, respectively. The proposed theory was validated on aluminum, steel, intact and damaged concrete samples. The obtained nonlinear parameters show reasonable agreement with values reported in the literature. Compared to other nonlinear acoustic methods using vibration or acoustic excitation, the thermal modulation method generates more uniform, slow changing, and larger strain field in the test sample. Employing the thermal effect as the driving force for nonlinearity instead of an undesired influencing factor, this method can measure the absolute values of α, β, and δ with good accuracy using a simple ultrasonic test setup.

Physics↗
DOE OSTI2020

Coupling of electroelastic dynamics and direct contact ultrasonic drying formulation for annular piezoelectric bimorph transducers

A newly developed technique for drying clothes without thermal energy has been developed through the utilization of ultrasonic vibrations from piezoelectric transducers. The novel technique incorporates the actuation of a thin stainless steel disk in contact with wet fabric via annular piezoelectric rings, where water in the liquid form is atomized, transported through microchannels in the disk, and ejected as a mist. In such a system, resonance matching between the actuation portion of the transducer and the portion contacting fabric must be realized, with theoretical results from the developed electromechanical model showing a reduction in energy consumption by 50% when resonance matching is achieved. The electrically coupled distributed parameter model for an annular bimorph piezoelectric transducer is developed for optimization of ultrasonic drying technology. The thickness mode vibrations are shown to dominate the behavior of the system, where the analytically developed model can be optimized to increase the output acceleration of the transducer, thus increasing drying performance. Here, the electromechanical equation developed will be connected to the drying rates of fabrics in contact with said vibrations, where the novelty of the coupled equations and its description of the physics of ultrasonic drying will be discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Contoured PPM-EMAT Design for Ultrasonic Communication On Metallic Pipe Channels

Ultrasonic guided waves can be used as the carriers of information in ultrasonic communication for pipe or plate channels. Permanent Periodic Magnet (PPM) Electromagnetic Acoustic Transducer (EMAT) can potentially provide unique capabilities for a communication system as a non-contact transmitter and receiver, which can selectively generate different modes of shear-horizontal (SH) waves. The SH wave shows the potentials in achieving high bitrate without error in ultrasonic communication. However, when a steel pipe is used as the communication channel, especially one with a radius comparable to the size of the transducer, no guided wave signal can be excited or detected by existing PPM-EMAT's with flat coupling surface. In this paper, a 3D printed magnet holder is designed which can shape the magnet array. Also, the transmitter/receiver coils are made of flexible printed circuit which can fit over the curvature of the pipe channels. The contoured PPM-EMAT transmitter and receiver can conform to the surface of the steel pipe channel in order to generate and detect torsional waves. Experimental tests of signal transmission with PPM-EMAT on a 160cm-long stainless steel pipe determine the optimal frequency for communication to be 916KHz. Information transmission experimental results confirm the validity of contoured PPM-EMAT for communication with a bitrate of 5kbps.

Huang, Xin↗
DOE OSTI2023

Machine-Learning Architecture for Ultrasonic Thermometry

Temperature distribution in solids can be inverted from the speed of sound (SOS) measurements, as has been shown feasible by timing the propagation of the excitation pulse and the train of echoes in ultrasonically segmented waveguides (WGs) and metal components. However, complicated geometries and closely-space echogenic features (EFs) create complex waveforms, from which the segmental time of flights (TOFs) are impossible to estimate using traditional methods. This work describes a machine learning architecture shown to extract temperature information from complex ultrasonic waveforms without explicit measurements of segmental TOFs. We accomplish this by using an autoencoder neural network (NN) to map ultrasonic waveforms into a low-dimensional latent space. A second NN then maps the latent space into unknown temperature distribution along the WG. The proposed architecture was tested in simulations and experimentally. The autoencoder accurately reconstructs the waveforms from their latent representation, several orders of magnitude lower in dimensionality. The obtained latent space was successfully mapped into the temperature of the propagation path.

John, Mason↗
DOE OSTI2021

Power Plant Testing of Ultrasonic Measurements of Temperature Distributions and Heat Fluxes to Heat Exchange Surfaces

Extreme environmental conditions are common in energy conversion applications, in which the most hardened insertion sensors often do not perform reliably for long. On the other hand, ultrasonic measurements can be acquired noninvasively, with sensitive components kept away from the damaging environment. We have previously developed the ultrasonic method for measuring the spatial distribution of temperatures in solid materials applicable when large thermal gradients are present. In the developed approach, we use the echogenically segmented ultrasound propagation path, structured to contain engineered or naturally occurring echogenic features, to produce a train of echoes in response to an external pulse of ultrasonic excitation. This paper outlines the testing results of this approach applied to the temperature distribution measurements to a waterwall of a 500 MW power-plant utility boiler. The validation results obtained over the prolonged power plant test show that the estimated temperature profile is correctly captured, and the measurement accuracy can be comparable with traditional insertion sensors, such as thermocouples. Overall, the testing has confirmed that the developed approach has matured to become an attractive alternative to conventional sensing in solving challenging problems of long-term temperature measurements in extreme environments. Heat fluxes and thermal stresses in the structure can then be characterized noninvasively using the measured temperature distribution as the basis.

Walton, Kenneth↗
DOE OSTI2020

Noncontact Flow Rate Using Laser Ultrasonics

Several types of advanced nuclear reactors are cooled with high-temperature liquid metal or molten salt flows. There is a critical need to measure flow velocity in flow channels for test purposes, and eventually in operational reactors. In conventional ultrasonic flow sensors, ultrasonic waves traveling in both the upstream and downstream directions are generated and detected by transducers that must contact the flow channels. A shift in the frequency or transit time between the two ultrasonic waves is measured to determine flow velocity. We describe here an initial effort to apply that sensing concept when the contact transducers are replaced by laser-based generation and detection instrumentation. This noncontact sensing avoids many practical problems associated with contact transducers when implemented on flow channels at high temperature. Laser-based flow monitoring can also be applied to hot-process piping in the geothermal energy, chemical-processing and petroleum-refining industries. Our effort has included theoretical simulation of noncontact laser-based flow monitoring, indicating capability of measuring flow velocities relevant to reactor cooling. It also included a room-temperature experimental demonstration using water as the flow liquid, and indicating capability of measuring flow velocity at a responsivity roughly consistent with simulation predictions. Plans were made for an experimental demonstration at Oregon State University using liquid metal at 110 degrees C.

02 PETROLEUM↗
DOE OSTI2023

In Situ Investigation of Upper Airway Occlusion in Sleep Disordered Breathing Using Ultrasonic Transducer Arrays

This work presents a novel application of ultrasound for the real-time, non-invasive investigation of occlusion of the upper airway during events of obstructive sleep apnea/hypopnea syndrome. It is hypothesized that ultrasonic pulses applied to the neck during apneic events produce spectral and temporal features that can detect apnea occurrence. Theoretical models of ultrasound propagation and an in vitro test were conducted to test this hypothesis in both transmission and reflection modes. Complete specifications and technical details of the system design and fabrication, which is mounted on each subject’s neck, are presented, including the methodology. Nine patients (seven male and two female, mean age of 42 years, with a range of 25 to 56 years, and body mass index 37.6 ± 6.6 kg/m2) were recruited for a full night study, which included simultaneous nocturnal polysomnography for the validation of the results. Nine temporal features and four spectral features were extracted from the envelope of the received pulse waveform. These were used to compute 26 metrics to quantify the changes in the ultrasonic waveforms between normal breathing and apneic events. The statistical analysis of the collected ultrasonic data showed that at least two or more of the proposed features could detect apneic events in all subjects. The findings establish the feasibility of the proposed method as a cost-effective and non-invasive OSAHS screening tool.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2023

Beta-Stabilized Ti-5Al-5Mo-5V-3Cr Primary and Secondary Phase Characterization using Ultrasonic Attenuation

Ti-5Al-5Mo-5V-3Cr (Ti-5553) is a beta-stabilized titanium alloy being evaluated for its use in additive manufacturing. The development of effective nondestructive characterization tools will be critical for successful insertion of Ti-5553 into applications. The microstructure of Ti-5553 can be modified significantly, through heat treatments alone, to produce single β-phase microstructure or dual α-β microstructure with variations on the types and quantities of the α phase in a β matrix. In this work, a set of heat treatments was chosen to obtain a range of microstructures, followed by an investigation of the ultrasonic response to gauge the degree to which these variations could be detected. Ultrasonic attenuation was selected because of its ability to detect differences in grain size and, potentially, the existence and limited details of secondary phases . Initial results show a very distinctive difference in attenuation between the single phase β and the α+β microstructures, and smaller, but still significant, differences among the α+β microstructures indicating that this approach merits further development.

ultrasonic attenuation, Ti-5Al-5Mo-5V-3Cr, heat tr↗
DOE OSTI2020

Surface engineering to enhance heat generation and joint strength in dissimilar materials AZ31 and DP590 ultrasonic welding

A multiscale simulation approach was developed and employed to optimize the sheet surface conditions for higher interfacial temperature and joint strength in ultrasonic welding of magnesium alloy AZ31 and dual-phase steel DP590. First, a mesoscale model was used to study the relationship between friction coefficient and surface roughness, which can be modified by various engineering methods. Then a macroscopic process model was employed to study the effects of surface roughness on heat generation, indicating that a temperature increase can be achieved with rougher surfaces on two sides of both DP590 and AZ31 sheets. Samples prepared by sanding and filing, as well as grinding, were first characterized for surface roughness and then welded under ultrasonic vibration. An infrared camera was used to measure temperatures in situ for model validation. Overall, lap shear test results for the welded joint showed that the joint strength can be improved by 10~25% using filing and round grinding methods as a result of the enhanced heat generation and mechanical interlocking on the interface.

42 ENGINEERING↗
DOE OSTI2022

On the efficacy of post-build thermomechanical treatments to improve properties of Zirconium fabricated using ultrasonic additive manufacturing

Here, hot-isostatic pressing has been applied to Zirconium plate fabricated using the ultrasonic additive manufacturing (UAM) technique to enhance interfacial bond quality. Specimens heated to 800 C for 1 h at 100 MPa pressure showed grain growth across many prior foil-to-foil interfaces, thereby increasing foil adhesion. In addition to the material softening induced by a loss of Hall-Petch strengthening, premature failure of specimens loaded parallel to the build direction was observed. Premature specimen failure was attributed to the local delamination at prior foil-to-foil boundaries where grain growth was pinned by Ti impurities introduced during the UAM process via the interaction between a Ti-alloy buffer foil and the welded Zr-foils underneath. In addition, the presence of Ti along select foil interfaces resulted in the nucleation and growth of secondary (Zr,Ti)(Fe,Cr) laves phases during higher-temperature thermomechanical processing. Using a combination of micro-scale X-ray computed tomography, fractography, and in-situ digital image correlation, the effect of defects along prior foil-to-foil boundaries was revealed as delamination-assisted plasticity accelerated specimen failure in preferred tensile orientations. These findings underscore the importance of impurity control when optimizing weld quality of higher-strength material systems using ultrasonic welding.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Visualization of hydraulic fracture using physics-informed clustering to process ultrasonic shear waves

Ultrasonic transmission is sensitive to the spatial variation in mechanical properties of materials due to the presence of cracks/fractures. Wave propagation through fractured media introduces changes in the frequency content, travel time and transmission coefficient of the wave. A workflow based on physics-informed unsupervised learning is developed to process the transmitted ultrasonic-shear waveforms to non-invasively visualize the geomechanical alterations due to hydraulic fracturing. Novelty of the work involves the assignment of both statistically consistent and physically consistent clusters to the measurements of shear waveforms acquired across the one axial and two frontal planes. Physically consistent/relevant information is incorporated by considering the travel time of the peak of spectral energy and transmission coefficient of the transmitted waveform. The proposed workflow generates maps of geomechanical alterations across the frontal and axial planes of the sample. The outputs of the workflow are in good agreement with independent techniques viz. acoustic emission and X-ray computed tomography. Finally, the proposed workflow can be adapted for improved fracture characterization in the subsurface when processing sonic-logging, cross-wellbore seismic or surface seismic waveform data.

42 ENGINEERING↗
DOE OSTI2024

Interface stability of ultrasonic additively manufactured Zircaloy-4 during hydrothermal corrosion

Simulated pressurized water reactor conditions (330 °C, 15.6 MPa, ~20 ppb oxygen) without irradiation were used to investigate the hydrothermal corrosion behavior of ultrasonic additively manufactured Zircaloy-4 up to 1000 h. X-ray computed tomography allowed for visualization of defects from processing and their progression after corrosion experiments. The specimens were found to have clear variability in the mass change data, compared to typical wrought Zircaloy-4 specimens. The variation in the mass change after exposure was attributed to weld defects connected to the specimen surface which allowed ingress of oxidant into the samples. Defects visualized by computed tomography were found via metallography and characterized. In conclusion, ultrasonic additively manufactured Zircaloy-4 was found to have comparable corrosion behavior as wrought Zircaloy-4 for specimens which did not have clear surface defects along weld interfaces.

36 MATERIALS SCIENCE↗
DOE OSTI2023

In situ synchrotron X-ray diffraction analysis of ultrasonically assisted microstructure refinement during laser melting process

This work investigates the effect of ultrasonic treatment (UST) on the microstructure of AA4043 alloy during laser melting process. Here, the study utilizes in situ synchrotron X-ray diffraction (SXRD) and postmortem electron backscatter diffraction (EBSD) techniques to examine the ultrasonic grain refinement mechanism. The SXRD diffraction patterns exhibit higher continuity of major diffraction rings in the UST-test pattern, indicating a more refined grain structure. The presence of new diffraction spots in the post-test diffraction pattern with UST suggests the breakdown of epitaxial growth of columnar dendrites during solidification. Thermal profiles determined by analyzing the lattice parameter evolution show a faster cooling rate with UST. The inverse pole figures and aspect ratio distribution from EBSD reveal that the UST samples exhibit a refined, more equiaxed grain structure along the weld centerline. UST sample also develops more fine-sized low angle grain boundaries (LAGBs). These features offer better hot-cracking resistance in aluminum alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Predicting Local Material Thickness from Steady-State Ultrasonic Wavefield Measurements Using a Convolutional Neural Network

Acoustic steady-state excitation spatial spectroscopy (ASSESS) is a full-field, ultrasonic non-destructive evaluation (NDE) technique used to locate and characterize defects in plate-like structures. ASSESS generates a steady-state, single-tone ultrasonic excitation in a structure and a scanning laser Doppler Vibrometer (LDV) measures the resulting full-field surface velocity response. Traditional processing techniques for ASSESS data rely on wavenumber domain analysis. This paper presents the alternative use of a convolutional neural network (CNN), trained using simulated ASSESS data, to predict the local plate thickness at every pixel in the wavefield measurement directly. The defect detection accuracy of CNN-based thickness predictions are shown to improve for defects of greater size, and for defects with higher thickness reductions. The CNN demonstrates the ability to predict thickness accurately in regions where Lamb wave dispersion relations are complex or unknown, such as near the boundaries of a test specimen, so long as the CNN is trained on data that accounts for these regions. The CNN also shows generalizability to ASSESS experimental data, despite an entirely simulated training dataset.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2023

Development and testing of coarse-grained models for ultrasonic simulations of cast austenitic stainless steel

Ultrasonic inspection of cast austenitic stainless steel (CASS) in the nuclear industry is particularly challenging because of sound field scatter and attenuation caused by the coarse-grained microstructure. Modeling and simulation are important tools in ultrasonic testing, as they can be used to help address key aspects of inspections, such as developing new probe designs, predicting inspection reliability, and testing phased-array focal laws. However, developing a useful and reliable CASS model is challenging due to the many grain interfaces and crystalline orientations that must be captured. We demonstrate a method of creating a realistic CASS model that is usable in CIVA, a commercially available modeling and simulation software platform. Using polished and chemically etched sections, we generate models of a coarse-grained equiaxed specimen and a columnar specimen. We also test an alternative method of generating a coarse-grained model using Voronoi regions. We qualitatively compare sound field scatter and quantitatively compare sound field attenuation and beam partitioning in simulated sound fields to those of laboratory-measured sound fields. Results show that the Voronoi models perform as well as or better than the models based on actual grain morphology. Here we also show that model-to-model randomness in Voronoi grain structure can impact the magnitude of a simulated echo response by a factor of two or more. Although CASS models are potentially a good depiction of reality for a given scenario, they should not be considered representative since CASS morphology can change significantly from specimen to specimen or within the same specimen.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Full waveform analysis for high pressure ultrasonic measurement

In this paper we report a data analysis protocol for ultrasonic velocity measurements carried out in a synchrotron x-ray facility based multi-anvil high-pressure apparatus. Synthetic ultrasonic signals for the time period between echoes from the two ends of the sample assembly are created with a few simple parameters as the echo waveform is modeled by the first echo from the anvil-assembly boundary. Each echo is modeled as a delta function with an amplitude and arrival time and convolved with this waveform. The final waveform, fit to the data, enables analysis of signals with overlapped echoes as they are common in small cell assemblies and high pressure.

47 OTHER INSTRUMENTATION↗
DOE OSTI2021

Ultrasonic oscillatory two-phase flow in microchannels

Experimental and numerical investigations are performed to provide an assessment of the transport behavior of an ultrasonic oscillatory two-phase flow in a microchannel. The work is inspired by the flow observed in an innovative ultrasonic fabric drying device using a piezoelectric bimorph transducer with microchannels, where a water-air two-phase flow is transported by harmonically oscillating microchannels. The flow exhibits highly unsteady behavior as the water and air interact with each other during the vibration cycles, making it significantly different from the well-studied steady flow in microchannels. Here, the computational fluid dynamics (CFD) modeling is realized by combing the turbulence Reynolds-averaged Navier-Stokes (RANS) k – ω model with the phase-field method to resolve the dynamics of the two-phase flow. The numerical results are qualitatively validated by the experiment. Through parametric studies, we specifically examined the effects of vibration conditions (i.e., frequency and amplitude), microchannel taper angle, and wall surface contact angle (i.e., wettability) on the flow rate through the microchannel. The results will advance the potential applications where oscillatory or general unsteady microchannel two-phase flows may be present.

42 ENGINEERING↗