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At least 919 records · Page 51

Micromachined Piezoresistive-sensed Diaphragms for Infrasonic Monitoring

Micromachined, piezoresistive-sensed diaphragms are designed and fabricated specifically for infrasound sensing applications. Relatively large diaphragms, up to 6 mm × 6 mm, are fabricated to meet the high sensitivity requirements of infrasonic monitoring. A double-stack SOI wafer process is used, resulting in a streamlined two-mask process without the need for doping or ion-implantation. Pressure-sensitivities of diaphragms are studied using a custom static calibration set-up. Here, the piezoresistance of longitudinal and transverse resistors are studied over a large pressure range of ±5,500 Pa so that the linear and nonlinear response regions of diaphragms are observed. Measurements are compared against a nonlinear finite element simulation—shown to accurately predict the sensor’s behavior over a large response range.

47 OTHER INSTRUMENTATION↗

Three-Dimensional Venturi Sensor for Measuring Extreme Winds

A three-dimensional (3D) Venturi sensor is being developed as a compact, rugged means of measuring wind vectors having magnitudes of as much as 300 mph (134 m/s). This sensor also incorporates auxiliary sensors for measuring temperature from -40 to +120 F (-40 to +49 C), relative humidity from 0 to 100 percent, and atmospheric pressure from 846 to 1,084 millibar (85 to 108 kPa). Conventional cup-and-vane anemometers are highly susceptible to damage by both high wind forces and debris, due to their moving parts and large profiles. In addition, they exhibit slow recovery times contributing to an inaccurately high average-speed reading. Ultrasonic and hot-wire anemometers overcome some of the disadvantages of the cup and-vane anemometers, but they have other disadvantageous features, including limited dynamic range and susceptibility to errors caused by external acoustic noise and rain. In contrast, the novel 3D Venturi sensor is less vulnerable to wind damage because of its smaller profile and ruggedness. Since the sensor has no moving parts, it provides increased reliability and lower maintenance costs. It has faster response and recovery times to changing wind conditions than traditional systems. In addition, it offers wide dynamic range and is expected to be relatively insensitive to rain and acoustic energy. The Venturi effect in this sensor is achieved by the mirrored double-inflection curve, which is then rotated 360 to create the desired detection surfaces. The curve is optimized to provide a good balance of pressure difference between sensor ports and overall maximum fluid velocity while in the shape. Four posts are used to separate the two shapes, and their size and location were chosen to minimize effects on the pressure measurements. The 3D Venturi sensor has smart software algorithms to map the wind pressure exerted on the surfaces of the design. Using Bernoulli's equation, the speed of the wind is calculated from the differences among the pressure readings at the various ports. The direction of the wind is calculated from the spatial distribution and magnitude of the pressure readings. All of the pressure port sizes and locations have been optimized to minimize measurement errors and to reside in areas demonstrating a stable pressure reading proportional to the velocity range.

Zysko, Jan A.↗

Supersonic Mass Flux Measurements via Tunable Diode Laser Absorption and Non-Uniform Flow Modeling

Measurements of mass flux are obtained in a vitiated supersonic ground test facility using a sensor based on line-of-sight (LOS) diode laser absorption of water vapor. Mass flux is determined from the product of measured velocity and density. The relative Doppler shift of an absorption transition for beams directed upstream and downstream in the flow is used to measure velocity. Temperature is determined from the ratio of absorption signals of two transitions (lambda(sub 1)=1349 nm and lambda(sub 2)=1341.5 nm) and is coupled with a facility pressure measurement to obtain density. The sensor exploits wavelength-modulation spectroscopy with second-harmonic detection (WMS-2f) for large signal-to-noise ratios and normalization with the 1f signal for rejection of non-absorption related transmission fluctuations. The sensor line-of-sight is translated both vertically and horizontally across the test section for spatially-resolved measurements. Time-resolved measurements of mass flux are used to assess the stability of flow conditions produced by the facility. Measurements of mass flux are within 1.5% of the value obtained using a facility predictive code. The distortion of the WMS lineshape caused by boundary layers along the laser line-of-sight is examined and the subsequent effect on the measured velocity is discussed. A method for correcting measured velocities for flow non-uniformities is introduced and application of this correction brings measured velocities within 4 m/s of the predicted value in a 1630 m/s flow.

Chang, Leyen S.↗

DECOVALEX-2023: Task C Final Report

The Full-scale Emplacement (FE) heater experiment at the Mont Terri Underground Rock Laboratory (URL) was designed and conducted by Nagra to replicate an emplacement tunnel of Nagra’s reference repository design at 1:1 scale. Alongside testing the technical feasibility of constructing disposal tunnels, emplacing waste containers in the tunnels and then backfilling them, the main goals of the FE experiment are (1) to obtain a better understanding of the coupled effects of induced thermo-hydro-mechanical (THM) processes that may occur and (2) to validate existing coupled THM models (Müller et al., 2017). A key aspect of ensuring safety for repositories located in low-permeability rock involves minimizing any damage to the rock itself, thereby preserving its integrity and promoting a stable environment Amongst a number of processes that could damage the rock is the increase in pore pressure due to thermal loading caused by heat emitted from the waste. To reduce the potential damage of the rock, it is important to analyse the evolution of heat over time due to the heat load of the containers and assess possible consequences by coupled THM models. The aim of Task C of DECOVALEX-2023 was to build 3D numerical models of the FE experiment, focussing in particular on the heating induced pore pressure change in the Opalinus Clay. Data from a large number of sensors were available from the FE experiment for model comparison. These sensors measured temperature and relative humidity in the bentonite around the heaters, and temperature, pressure and displacement/strain in the surrounding Opalinus clay. Data were available from the start of excavation (April 2012) up to August 2020 for most sensors (more than 5 years from the start of heating in December 2014). To fulfil the overall aim of the task, the work was broken down into a number of steps, starting with simpler models to build confidence in each team’s approach and then moving to more complex models that better represent the FE experiment. Step 0 consisted of 2D benchmark models, gradually increasing the number of processes that are represented from thermal (T) only models in Step 0a, to coupled thermal hydraulic (TH) models in Step 0b with a representation of changing porosity, to coupled thermo-hydro-mechanical (THM) models in Step 0c, where porosity changes are calculated by the mechanical model. A detailed specification of processes, parameters, initial and boundary conditions was provided for this step, with the ambition that all teams would work towards close agreement in their model results, thus building confidence in the model implementations. vi It was not straightforward to achieve agreement between the teams, so additional steps (Step 0b2, 0b3, 0c2, 0c3) were added along with derivation of some analytical solutions against which the models could be compared. The reasons for the differences between teams were investigated and found to be caused primarily by different conceptual model assumptions (including temperature dependence of the thermal expansion of water), different model formulations (including porosity evolution) and differences in modelled domain sizes, boundary conditions and grid discretisation. This demonstrates that comparisons between multiple modelling teams and/or comparison with analytical results and experimental data are highly beneficial in providing an indication of uncertainty in model predictions. At the conclusion of Step 0, almost all teams had achieved a close agreement in model results and those that had not achieved an agreement knew the reason for this. Step 1 moved from 2D models to 3D models of the FE experiment without adding technical features like shotcrete or EDZ, and only considering the heating phase. Initially the 3D model was tightly specified to continue to build confidence in the model implementations (Step 1a). The results of Step 1a were compared to the data from the FE-experiment without the teams seeing the data. The teams were then provided with a sub-set of the data from the FE-experiment and invited to consider how best to use the large dataset for model comparison (Step 1b). Teams were then asked to use the data provided to calibrate their models, only changing material property values rather than adding features or processes to their models (Step 1c). In Step 1, teams were asked to only model the heating phase of the experiment, so pressure in the Opalinus Clay was reported as change in pressure since the initial conditions were specified rather than modelled. The change from 2D to 3D models was accompanied by an increase in the dispersion of results between the teams. Some of this was resolved during the task, but some remained and is potentially due to model discretisation. Calibration of parameters was useful in improving the fit of the models to the data but the remaining differences indicated that the models were missing features or processes. In Step 2, the teams were asked to update their models with additional features and processes as well as calibrating parameters to try and improve the fit of the models to the data. Teams were encouraged to represent ventilation of the open FE tunnel prior to backfilling with heaters and bentonite and in Step 2, the absolute pressure in the Opalinus Clay was compared between the teams. Teams took different approaches, but there was consideration of adding shotcrete and an EDZ into the model, representing stress change during excavation and different approaches to modelling ventilation of the FE tunnel. Overall, the documented results showed a very good agreement for temperature. The results for porewater pressure evolution showed a significant improvement for most teams compared to Step 1c with a good agreement to the measurements for several teams whereas some teams overpredicted the pressure increase and others overpredicted the drainage effect especially for the sensors close to the heater. Step 3 was an opportunity for teams to use the models developed in Step 1 and Step 2 to make predictions about the temperature and pressure changes that will be expected at the FE experiment over the next few years in light of the planned changes in thermal output of the heaters.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

A numerical field experiment approach for determining probabilities of microburst intensity

Several investigators had determined that some atmospheric parameters were related to the formation and severity of microbursts. For example, Caracena pointed out the relationship between a dry adiabatic lapse rate and microbursts in 'The crash of Delta Flight 191 at Dallas-Fort Worth international airport'. These early investigations led to the idea that numeric modeling of microbursts with varying atmospheric parameters might define 'signatures' that could lead to determining the probability of microburst intensity. The idea was that, by using already available sensors (such as static air temperature, pressure altitude, and radar reflectivity) onboard an aircraft, a reliable prediction of microburst existence and intensity could be formed. Such data could be used to create an 'expert meteorologist' using either artificial intelligence or other techniques that could be used in either reactive or look-ahead systems to vary sensitivity thresholds and coordinate the inputs from different detecting systems. To this end, Honeywell contracted to have the microburst simulations run. The questions to be addressed were the following: using the sensor set available to the aircraft (e.g. temperature, radar reflectivity, etc.), can we calculate the probability that (1) a microburst could be formed? and (2) that the resultant winds would be of sufficient magnitude to threaten the aircraft? Over a two year period, a data set of 1800 microburst simulations was accumulated. Verification of the microburst simulation was obtained using the results of other independent researchers and actual comparison to microburst events in Orlando and Denver. Some of the results from the simulation have already been incorporated into Honeywell's Windshear Detection and Guidance System with excellent results. Various aspects of this investigation are presented in viewgraph form.

Droegemeier, Kelvin K.↗

A program to evaluate a control system based on feedback of aerodynamic pressure differentials. Part 2: Data report for phase 1 wind tunnel test

Wind tunnel test data are presented. The purpose of the test was to determine the sensor location for sensitivity to flap deflection and to determine the range required of the sensor. The calculations followed to correct the raw pressure measurements, the corrected measurements, which represent the static pressures along the airfoil surface, and the static pressures tabulated and in coefficient form are described. However, the chordwise locations of the upper and lower surface taps do not coincide. An interpolation routine is performed to find the lower surface pressure coefficients at the upper surface tap locations. The difference, C sub P(lower) - C sub P(upper), is calculated and listed and the data are reorganized with respect to each tap location. A numerical regression performed to quantify the slopes of the graphs allows more accurate comparison of sensitivity and linearity.

Hrabak, R. R.↗

Sensitivity of thermodynamic profiles retrieved from ground-based microwave and infrared observations to additional input data from active remote sensing instruments and numerical weather prediction models

Accurate and continuous estimates of the thermodynamic structure of the lower atmosphere are highly beneficial to meteorological process understanding and its applications, such as weather forecasting. In this study, the Tropospheric Remotely Observed Profiling via Optimal Estimation (TROPoe) physical retrieval is used to retrieve temperature and humidity profiles from various combinations of input data collected by passive and active remote sensing instruments, in situ surface platforms, and numerical weather prediction models. Among the employed instruments are microwave radiometers (MWRs), infrared spectrometers (IRSs), radio acoustic sounding systems (RASSs), ceilometers, and surface sensors. TROPoe uses brightness temperatures and/or radiances from MWRs and IRSs, as well as other observational inputs (virtual temperature from the RASS, cloud-base height from the ceilometer, pressure, temperature, and humidity from the surface sensors) in a physical iterative retrieval approach. This starts from a climatologically reasonable profile of temperature and water vapor, with the radiative transfer model iteratively adjusting the assumed temperature and humidity profiles until the derived brightness temperatures and radiances match those observed by the MWR and/or IRS instruments within a specified uncertainty, as well as within the uncertainties of the other observations, if used as input. In this study, due to the uniqueness of the dataset that includes all the above-mentioned sensors, TROPoe is tested with different observational input combinations, some of which also include information higher than 4 km above ground level (a.g.l.) from the operational Rapid Refresh numerical weather prediction model. These temperature and humidity retrievals are assessed against independent collocated radiosonde profiles under non-cloudy conditions to assess the sensitivity of the TROPoe retrievals to different input combinations.

54 ENVIRONMENTAL SCIENCES↗

Predictive sensor method and apparatus

A predictive algorithm is used to determine, in near real time, the steady state response of a slow responding sensor such as hydrogen gas sensor of the type which produces an output current proportional to the partial pressure of the hydrogen present. A microprocessor connected to the sensor samples the sensor output at small regular time intervals and predicts the steady state response of the sensor in response to a perturbation in the parameter being sensed, based on the beginning and end samples of the sensor output for the current sample time interval.

Nail, William L.↗

Noninvasive Breath Analysis Using NASA E-Nose Technology for Health Assessment

Clinical breath analysis is based on the fact that many important metabolites and biomarker molecules are present at detectable levels in exhaled breath, and many of these molecules correlate with human disease or correlate with physiological states that could lead to a decline in health. Presented is a technology that utilizes an array of chemical sensors combined with humidity, temperature and pressure for real time breath analysis to correlate the chemical information in the breath with the state and functioning of different human organs. For example, a marker for pulmonary inflammation processes of the lower respiratory tract, e.g. asthma, is the increase of the nitrogen oxide (NO) concentration in breath. Other volatile biomarkers may correlate with infectious process, metabolic conditions and inflammatory diseases, such as traumatic brain injury (TBI). This technology is also called "electronic nose" (E-Nose) in the sense that the device can mimic human nose to smell odors using a pattern recognition technique to analyze the sensor array data. Breath sampling is non-invasive and can be analyzed in real-time.

Li, Jing↗

High sensitivity pressure and temperature quantum sensing in pentacene-doped p-terphenyl single crystals

Quantum sensors’ responsiveness to their physical environment enables detection of variables such as temperature (T), pressure (P), and strain. We present a molecular platform for PT sensing using para-terphenyl crystals doped with pentacene (PDP), leveraging optically detected magnetic resonance (ODMR) of photoexcited triplet electron spins. We observe maximal frequency variations of df/dP=1.8 MHz/bar from 0-8 bar and df/dT=247 kHz/K from 79–330 K, over 1200 times and threefold greater, respectively, than those seen with nitrogen-vacancy centers in diamond and > 85-fold greater pressure sensitivity over the previous record. Density functional theory calculations indicate picometer-level PT-induced molecular orbital shifts are measurable via ODMR. PDP offers additional advantages including high sensor doping levels, narrow ODMR linewidths, high contrast, and low-cost single crystal growth. Overall, this work reports low-cost, optically-interrogated PT sensors and lays the foundation for increased versatility of quantum sensors through synthetic molecular design.

Magnetic properties and materials↗

Unsteady Pressure Acquisition on the 1.75% Scale SLS Block 1B Cargo Liftoff Configuration

Time-varying pressure on the core of the Space Launch System (SLS) Block 1B Cargo vehicle was acquired using instrumentation typically used for steady, time averaged pressure. Resono Pressure Systems, Inc. in partnership with the University of Wyoming have developed a unique hardware and software system for measuring unsteady pressure, which was implemented in a large-scale wind tunnel test through a nonreimbursable Space Act Agreement with NASA. The technique was applied to 12 pressure ports on the 1.75% scale SLS wind tunnel model. Tubing lengths of approximately 14 inches separated the pressure transducer module from the pressure taps on the model surface, and surface-mount validation sensors (Kulites) were installed in close proximity to 5 of the 12 pressure ports. Up to about 500 Hz, the frequency response of pressure fluctuations agreed to within 1 dB of amplitude and 10° of phase difference compared to the simultaneously-acquired surface-mount transducers. Sample results using the reconstructed pressure from the full azimuthal ring of taps are presented.

unsteady pressure↗

Flow Boiling and Condensation Experiment: Flow Boiling in a Rectangular Channel with Subcooled Inlet Conditions in Microgravity

Two-phase thermal management subsystems that take advantage of both the sensible and latent heat of a working fluid can potentially yield significant enhancements in overall performance by adopting heat transfer processes that are based on phase transition like boiling and condensation. Performance of terrestrial two-phase flow systems may be predictable because the hydrodynamic and body forces are understood, however, in microgravity, which is predominant during planetary space travel, forces that are masked by the strong body force on Earth (gravitational or buoyancy force) reappear with different magnitude and influence. The need arose for a facility that provides for two-phase flow with phase transition testing in microgravity. The Flow Boiling and Condensation Experiment (FBCE) is a facility that was launched to the International Space Station in August of 2021 and is in operation since February of 2022. This facility enables investigators to perform two-phase flow and phase transition research in flow boiling and condensation. Along with the test module that is experiment specific, the FBCE system consists of the fluid, avionics, and software subsystems. Currently two test modules, namely, the Flow Boiling Module (FBM) and the Condensation Module for Heat Transfer (CM-HT) are available. A third module, the Transfer Line test Module (TL) is being developed. The fluid subsystem conditions and delivers the fluid at the desired thermodynamic state to the test module. It consists of two fluid modules and a heater module that are connected by flex hoses for fluid circulation and by data and electrical cables for control and data acquisition. Two avionics modules acquire pressure and temperature data from various sensors in the flow loop. For FBM, a high-speed camera is available to acquire images of the boiling process. Experiments are operated autonomously by software and are based on an Experiment Parameters Master Table (EPMT) that is uploaded to ISS and is executed by the FBCE flight software. This presentation briefly introduces the objectives of FBCE and provides a system description of the experiment onboard of the ISS/Fluid Integrated Rack (FIR). Results of the test campaign carried out using the FBM are presented. Specifically, microgravity flow boiling of n-perfluorohexane (test fluid) is discussed with subcooled inlet conditions in a single-side-heated rectangular channel of dimensions 114.6-mm heated length, 2.5-mm heated width, and 5.0-mm height. Key operating parameters investigated are mass velocity (199.90 – 3200.13 kg/m2s), inlet subcooling (0.10 – 45.76°C), and inlet pressure (113.30 – 164.29 kPa). Image sequences acquired via high-speed-video are shown to elucidate the interfacial flow physics. The effects of various parameters on flow boiling heat transfer in microgravity, from the onset of boiling to the critical heat flux are discussed. Heat transfer results are presented in terms of flow boiling curves, streamwise profiles of wall temperature and heat transfer coefficient, and parametric trends of local and averaged heat transfer coefficient, and the critical heat flux.

Two-phase flow and phase transition↗

Groundwater level elevation and temperature data, Oct 2018-Dec 2021, Slate River Floodplain, Crested Butte, CO

This data package includes a time series of water level and temperature measurements from October 2018 to December 2021 in groundwater and surface water from the Slate River floodplain outside Crested Butte, CO, a focus field site for the SLAC Floodplain Hydro-Biogeochemistry SFA. The data was generated as part of the work targeting the overarching research question for the SLAC SFA: How do ubiquitous subsurface interfaces mediate molecular-scale biogeochemical processes and groundwater quality in floodplains and watersheds? The data were recorded by pressure transducers were installed in four types of piezometers: 1) a network of gravel bed ("GB") drive-point piezometers with a 6-inch screen interval installed all at ~330 cm below ground surface. 2) a network of piezometers screened across the water table, used to measure evapotranspiration ("ET") using the White method. Each of these piezometers is screened along almost its entire length.3) a suite nested piezometers used the measure the vertical hydraulic gradient ("VHG") across the fines-cobble interface. Each of these piezometers uses a 6-inch screen length.4) a group of piezometers scattered across the boundaries of the floodplain, used to monitor boundary conditions ("BC") flowing into and out of the floodplain. With the exception of "SR-BD-WT", each of these piezometers is screened along its entire length. Within the data package, "FLMD.csv" describes file-level metadata and "dd.csv" defines column headers and universal terms across the dataset. The data package includes 11 "*data.csv" files, one for each piezometer type for each calendar year. Because piezometers have been added over time, not every sensor has data dating back to Oct 2018. Each "*data.csv" file has a corresponding "*_InstallationMethods.csv" file that describes the location, elevation, screen depth, sediment type and sensor metadata for each piezometer and pressure transducer.

54 ENVIRONMENTAL SCIENCES↗

Design development and test: Two-gas atmosphere control subsystem

An atmosphere control subsystem (ACS) was developed for NASA-IBJSC which is designed to measure the major atmospheric constituents in the manned cabin of the space shuttle orbiter and control the addition of oxygen and nitrogen to maintain the partial pressures of these gases within very close limits. The ACS includes a mass spectrometer sensor (MSS) which analyzes the atmosphere of a shuttle vehicle pressurized cabin, and an electronic control assembly (ECA). The MSS was built and tested to meet the requirements for flight equipment for the M-171 Metabolic Analyzer experiment for the Skylab flight program. The instrument analyzes an atmospheric gas sample and produces continuous 0-5 vdc analog signals proportional to the partial pressures of H2, O2, N2, H2O, CO2 and total hydrocarbons having a m/e ratio between 50 and 120. It accepts signals from the MSS proportional to the partial pressures of N2 and O2 and controls the supply of these gases to the closed cabin.

Jackson, J. K.↗

Probabilistic risk analysis of flying the space shuttle with and without fuel turbine discharge temperature redline protection

An exact mathematical model is presented of the Space Shuttle Main Engine computer voting logic in the presence of High Pressure Fuel Turbine (HPFT) overtemperature events and fuel turbine temperature sensor failures. The model provides estimates of the probability of erroneous engine shutdown and the probability of not detecting a HPFT overtemperature event. Because it is believed that the likelihood of sensor failures and overtemperature events in the HPFT greatly overshadows those in the High Pressure Oxygen Turbine (HPOT), this modeling effort focused on the HPFT. However, because the redline protection logic is the same for both turbines, estimation of the model parameters using relevant HPOT data would provide estimates of the risk of erroneous engine shutdown and an undetected overtemperature event in the HPOT. Because of the complexity of the model, it was necessary to program the solution which thus makes it feasible to accommodate a changing data base. This is considered to be of great interest because of the subjective nature in determining the relevancy of certain failures and the fact that the data base is constantly changing as a result of the frequent engine tests.

Howell, Leonard↗

Electro-optic architecture (EOA) for sensors and actuators in aircraft propulsion systems

Results of a study to design an optimal architecture for electro-optical sensing and control in advanced aircraft and space systems are described. The propulsion full authority digital Electronic Engine Control (EEC) was the focus for the study. The recommended architecture is an on-engine EEC which contains electro-optic interface circuits for fiber-optic sensors on the engine. Size and weight are reduced by multiplexing arrays of functionally similar sensors on a pair of optical fibers to common electro-optical interfaces. The architecture contains common, multiplex interfaces to seven sensor groups: (1) self luminous sensors; (2) high temperatures; (3) low temperatures; (4) speeds and flows; (5) vibration; (6) pressures; and (7) mechanical positions. Nine distinct fiber-optic sensor types were found to provide these sensing functions: (1) continuous wave (CW) intensity modulators; (2) time division multiplexing (TDM) digital optic codeplates; (3) time division multiplexing (TDM) analog self-referenced sensors; (4) wavelength division multiplexing (WDM) digital optic code plates; (5) wavelength division multiplexing (WDM) analog self-referenced intensity modulators; (6) analog optical spectral shifters; (7) self-luminous bodies; (8) coherent optical interferometers; and (9) remote electrical sensors. The report includes the results of a trade study including engine sensor requirements, environment, the basic sensor types, and relevant evaluation criteria. These figures of merit for the candidate interface types were calculated from the data supplied by leading manufacturers of fiber-optic sensors.

Glomb, W. L., Jr.↗

New Research Methods Developed for Studying Diabetic Foot Ulceration

Dr. Brian Davis, one of the Cleveland Clinic Foundation's researchers, has been investigating the risk factors related to diabetic foot ulceration, a problem that accounts for 20 percent of all hospital admissions for diabetic patients. He had developed a sensor pad to measure the friction and pressure forces under a person's foot when walking. As part of NASA Lewis Research Center's Space Act Agreement with the Cleveland Clinic Foundation, Dr. Davis requested Lewis' assistance in visualizing the data from the sensor pad. As a result, Lewis' Interactive Data Display System (IDDS) was installed at the Cleveland Clinic. This computer graphics program is normally used to visualize the flow of air through aircraft turbine engines, producing color two- and three-dimensional images.

Source record↗

Design and Analysis of a Mutual Inductance Level Sensor for Liquid Metals

Here, this article describes the design and analysis of an electromagnetic level sensor for use in high-temperature liquid metal systems. The mutual inductance level sensor (MILS) described in this work was fabricated using two single-conductor mineral insulated cables wrapped in a bifilar fashion around a stainless steel tube core and was housed in an isolating thimble that preserved the pressure boundary of the test vessel. Two sensor variations were fabricated that differ only in active length, 1016 and 1778 mm. Experimental data were collected using the 1016-mm sensor (MILS-MKII-040) that demonstrated a sensitivity of 9.2 μ V/mm in a room temperature testing stand that used solid aluminum as a surrogate for liquid metal. Experimental data were collected using the 1778-mm sensor (MILS-MKII-070) that demonstrated a sensitivity of 6.9 μ V/mm in the high-temperature (300 ° C) liquid sodium environment at the mechanisms engineering test loop (METL) of Argonne National Laboratory. The sensor performance was found to be repeatable over the course of several months, with roughly ±1% deviation from nominal output. Finite element models were developed in COMSOL Multiphysics that fully describe each test setup, and the models were validated using experimental data. The validated COMSOL models were used to perform an array of analyses that examined the performance of the sensor in differing environments. Maximizing the coil diameter inside the isolating thimble was found to maximize the signal and sensitivity of the sensor. An optimal operating frequency was found near 1000 Hz using both experimental data and COMSOL. The influence of a metallic thimble surrounding the sensor and a metallic sensor core was quantified and found to be negligible at the optimal operating frequency. The sensitivity of the sensor was quantified when monitoring the level of additional liquid metals. These include lead, lead-bismuth eutectic (LBE), sodium-potassium alloy (NaK), and lithium (in addition to sodium). The sensitivities were quantified using liquid metal properties at 350 ° C and 650 ° C. The geometry of the test stand model, all material properties used in the model, and the results are presented in a manner that allows the reader can replicate the model and perform additional analyses.

COMSOL↗