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DOE OSTI2024

ThermoPore: Predicting part porosity based on thermal images using deep learning

Part qualification is often a critical and labor-intensive process in additive manufacturing, particularly in the detection of defects such as porosity, which stands to benefit significantly from advancements in machine learning. We present a deep learning approach for quantifying and localizing ex-situ porosity within Laser Powder Bed Fusion fabricated samples utilizing in-situ thermal image monitoring data. Our goal is to build the real time porosity map of parts based on thermal images acquired during the build. The quantification task builds upon the established Convolutional Neural Network model architecture to predict pore count and the localization task leverages the spatial and temporal attention mechanisms of the novel Video Vision Transformer model to indicate areas of expected porosity. Our model for porosity quantification achieved a R 2 score of 0.57 and our model for porosity localization produced an average Intersection over Union (IoU) score of 0.32 and a maximum of 1.0. This work is setting the foundations of part porosity “Digital Twins” based on additive manufacturing monitoring data and can be applied downstream to reduce time-intensive post-inspection and testing activities during part qualification and certification. In addition, we seek to accelerate the acquisition of crucial insights normally only available through ex-situ part evaluation by means of machine learning analysis of in-situ process monitoring data.

Deep learning↗

NASA NTRS2008

A Wide Spectrum of Solar Science for After School Astronomy Club

After School Astronomy clubs are an important method of exposing students to astronomy at the critical middle school age when sparking an interest can inspire a lifelong career or hobby. We know that teachers complain that they can spend little time on astronomy in the classroom since they must teach to the test and the curriculum requirements do not have very extensive astronomy coverage. We also know that space is a very popular subject with students that can motivate them to join an after school club. One of the problems with after school astronomy clubs is that they don't often have a chance to observe the night sky. We propose to train club mentors on how to do daytime solar observing so students fulfill the IYA goal of looking through a telescope. We propose to provide a half day workshop for elementary and middle school teachers on starting and maintaining After School Astronomy clubs with special emphasis on observing the Sun not only in the visible spectrum but with radio waves and other parts of the spectrum as well. We will use NASA-oriented or NASA-funded educational materials and websites to bring a variety of ideas to the mentors and a broad knowledge of astronomy to the students. Attendees will be given an overview of the science of the Sun and how it can affect us on the Earth. They will be shown the dynamic nature of the Sun and what to look for to track the events happening there. The educators will be shown simple approaches to directly observing the Sun such as pinhole cameras, use of projection techniques with telescopes or binoculars, etc. They will be acquainted with sunspotter scopes and the advantages and disadvantages (such as expense) they pose for getting students involved. We will also point out the possibilities of using regular telescopes with solar filters and the specialized solar viewing telescopes such as the Coronado. Once the educators are comfortable with the simple approaches to viewing the Sun we will expose them to advanced topics such as remotely viewing the Sun using telescopes available on the web. Resources such as the Sun-Earth Viewer will allow them to study near real-time images of the Sun in multiple wavelengths. They will also be shown how they can monitor the Sun at radio wavelengths via remote telescopes or even how to purchase and build their own radio telescopes for hands-on monitoring of the Sun and other radio sources. We will conduct a brief evaluation of the participants knowledge of the Sun as they come into the workshop. We will also ask them to complete a brief knowledge survey at the end to determine if their knowledge and comfort level with solar science has improved significantly.

Mayo, Lou↗

NASA NTRS2001

NASA Ames Research Center 60 MW Power Supply Modernization

The NASA Ames Research Center 60 MW DC Power Supply was built in 1974 to provide controlled DC power for the Thermophysics Facility Arc Jet Laboratory. The Power Supply has gradually losing reliability due to outdated technology and component life limitation. NASA has decided to upgrade the existing rectifier modules with contemporary high-power electronics and control equipment. NASA plans to complete this project in 2001. This project includes a complete replacement of obsolete thyristor stacks in all six rectifier modules and rectifier bridge control system. High power water-cooled thyristors and freewheeling diodes will be used. The rating of each of the six modules will be 4000 A at 5500 V. The control firing angle signal will be sent from the Facility Control System to six modules via fiberoptic cable. The Power Supply control and monitoring system will include a Master PLC in the Facility building and a Slave PLC in each rectifier module. This system will also monitor each thyristor level in each stack and the auxiliary equipment.

Choy, Yuen Ching↗

NASA NTRS2015

Intelligent Hardware-Enabled Sensor and Software Safety and Health Management for Autonomous UAS

Unmanned Aerial Systems (UAS) can only be deployed if they can effectively complete their mission and respond to failures and uncertain environmental conditions while maintaining safety with respect to other aircraft as well as humans and property on the ground. We propose to design a real-time, onboard system health management (SHM) capability to continuously monitor essential system components such as sensors, software, and hardware systems for detection and diagnosis of failures and violations of safety or performance rules during the ight of a UAS. Our approach to SHM is three-pronged, providing: (1) real-time monitoring of sensor and software signals; (2) signal analysis, preprocessing, and advanced on-the- y temporal and Bayesian probabilistic fault diagnosis; (3) an unobtrusive, lightweight, read-only, low-power hardware realization using Field Programmable Gate Arrays (FPGAs) in order to avoid overburdening limited computing resources or costly re-certi cation of ight software due to instrumentation. No currently available SHM capabilities (or combinations of currently existing SHM capabilities) come anywhere close to satisfying these three criteria yet NASA will require such intelligent, hardwareenabled sensor and software safety and health management for introducing autonomous UAS into the National Airspace System (NAS). We propose a novel approach of creating modular building blocks for combining responsive runtime monitoring of temporal logic system safety requirements with model-based diagnosis and Bayesian network-based probabilistic analysis. Our proposed research program includes both developing this novel approach and demonstrating its capabilities using the NASA Swift UAS as a demonstration platform.

Robotics↗

NASA NTRS1995

Optoelectronic Particle-Fallout Sensor

Portable optoelectronic system monitors fallout of small particles (dust and fibers) onto surface at given location during extended time. Data on accumulated fallout downloaded from system to computer for display and analysis. Typical display is plot of signal proportional to amount of accumulated fallout as function of time and read to determine when contamination occurs. In many cases, possible to establish correlations between accumulations of particles and activities in vicinity. Also capable of signaling alarm in event contamination by fallout exceeds specified level. System made very inexpensively and used to monitor accumulation of dust and fibers associated with motion of air in variety of environments. Phenomena monitored indirectly by use of system might include circulation of air in buildings, and human and animal activity. Also serves as auxiliary intrusion monitor (though probably not real-time alarm) in sealed room because motion of intruder inevitably stirs up some dust.

Ihlefeld, Curtis↗

NASA NTRS1994

Self-calibrating models for dynamic monitoring and diagnosis

The present goal in qualitative reasoning is to develop methods for automatically building qualitative and semiquantitative models of dynamic systems and to use them for monitoring and fault diagnosis. The qualitative approach to modeling provides a guarantee of coverage while our semiquantitative methods support convergence toward a numerical model as observations are accumulated. We have developed and applied methods for automatic creation of qualitative models, developed two methods for obtaining tractable results on problems that were previously intractable for qualitative simulation, and developed more powerful methods for learning semiquantitative models from observations and deriving semiquantitative predictions from them. With these advances, qualitative reasoning comes significantly closer to realizing its aims as a practical engineering method.

Kuipers, Benjamin↗

NASA NTRSDate not supplied

Method Development for Multiplex, In-Situ, and Real-Time Detection of Herpesvirus Reactivation in Spaceflight Crews using Nanopore Sequencing

Reactivation of latent herpesviruses in crews onboard the International Space Station (ISS) is a well-established spaceflight-associated phenomenon and has been linked to overall immune stress. Beyond an indicator of an altered immune state, this stress-induced reactivation of viruses such as herpesvirus simplex virus 1 (HSV-1), Epstein-Barr virus (EBV), and Varicella-Zoster virus (VZV) may cause clinical symptoms in crew. There is currently no established protocol for in-flight monitoring, and samples are analyzed post-flight using ground-based assays. A real-time, in-flight method for herpesvirus detection followed by stress-mitigation strategies would be a significant advance. In this study, we developed a real-time assay for the multiplex detection of HSV-1, EBV, and VZV from saliva that could be implemented for in-situ monitoring of ISS crew. This method builds on previously validated spaceflight-compatible portable molecular protocols and platforms, such as the miniPCR thermal cycler and the MinION sequencer. Since a metagenomic approach is not currently permitted for crew samples (NASA policy), we employed multiplexing-ready primers directed toward targeted regions within the HSV-1, EBV, and VZV genomes. We also used primers for the human gene, Statherin (STATH), as an internal control. These primers were validated using spiked-in, positive control HSV-1, EBV, and VZV from virus-negative saliva extracted using the Zymo-Research Quick-DNA/RNA Viral MagBead Kit. The PCR Barcoding Kit was used to prepare DNA libraries that were then sequenced on the MK1C and analyzed against known reference genomes using minimap2. Following validation of this method with spiked saliva samples, suspected herpesvirus-positive clinical saliva samples were successfully tested. Prior to use onboard the ISS, this method will be deployed to an analog environment during overwintering at Palmer Station, Antarctica in 2023. This work represents the successful application of molecular technologies currently onboard the ISS for the real-time monitoring of latent herpesvirus reactivation from saliva samples. This assay, in combination with stress-reduction strategies, holds the potential to manage herpesvirus reactivation in ISS crew, thereby improving health outcomes and overall immunity.

Patrick M. Rydzak↗

NASA NTRS1986

Variation of the urban NO2 concentration during a ground inversion situation

In February 1985 the NO2 concentration over Goeteborg, a major Swedish city, was monitored during two inversion situations. The differential absorption technique was employed and the results show the build-up of the concentration. In this experiment the laser beam was scanned horizontally over Goeteborg. The results were presented as maps over the NO2 concentration distribution. For security reasons the beam was not parallel to the ground, which gives a height gradient in some measurements. During the measurement period the NO2 concentration variation build-up from the morning to the afternoon was monitored. Great concentration variations were seen. Later the mixing below the inversion layer, resulting in a more uniform, high concentration was seen. The breakdown of the inversion when stronger winds start was also seen. Comparisons with a traditional point-measuring chemiluminiscence instrument and an optical method DOAS (Differential Optical Absorption Spectroscopy), were made. The results are discussed. Strong spatial concentration variations are shown by the lidar measurements. For a point-measuring system, the instrument must be very carefully placed since its location will strongly influence the values it gives.

Sunesson, A.↗

DOE OSTI2024

Triton Initiative: FY 2024 Communications, Outreach, and Engagement End-of-Year Report

The Department of Energy (DOE) Water Power Technologies Office (WPTO) Triton Initiative works to reduce barriers to permitting of marine energy testing and installation through environmental monitoring research that can help inform decision-makers on potential environmental effects associated with these systems. Communications, outreach, and engagement efforts are critical to Triton's success, which involves facilitating the effective communication and dissemination of environmental monitoring research information and results to end-users and fostering collaborations between researchers and industry partners to address the most pressing needs of this emerging industry. The Triton Initiative's communications, outreach, and engagement (TCOE) foundational goals are to educate and raise awareness of ME and the role of Triton's environmental monitoring research in supporting the industry, build trust with audiences through transparent communications and outreach, and evaluate and refine TCOE tactics based on feedback and metrics. The TCOE FY 2024-specific objectives were to (1) refine and grow Triton's audience network by reaching new individuals and communities within Triton's target audience base, and (2) improve the strategy and evaluation of TCOE efforts to demonstrate the value of communications and outreach for the ME community. This report presents the results and analysis of communications activities from September 1, 2023 through August 31, 2024. We assess the TCOE target audiences, highlight notable successes and lessons learned from FY2024, and identify the most effective channels and activities used to connect with those audiences to achieve the TCOE goals.

16 TIDAL AND WAVE POWER↗

NASA NTRS1971

Water Pollution Detection by Reflectance Measurements

Measurement of the intensity of light reflected from various planar liquid surfaces has been performed. The results of this brief study show that the presence of a film of foreign material floating on a reference substrate is easily detected by reflectance measurement if the two liquids possess significantly different refractive indices, for example, oil (n = 1.40) and water (n = 1.33). Additional study of various optical configurations, and the building and testing of a prototype monitoring device revealed that the method is sufficiently practical for application to continuous water quality monitoring.

Goolsby, A. D.↗

NASA NTRS1989

Manufacturing Aids

During a research program, MMTC/Textron invented a computer-aided automatic robotic system for spraying hot plasma onto a turbine blade. The need to control the thickness of the plasma deposit led to the development of advanced optical gaging techniques to monitor and control plasma spray build-up on blade surfaces. The techniques led to computerized optical gages for inspecting aircraft, industrial turbine blades, etc. MMTC offers 10 standard commercial robotic gages. The system also generates two dimensional profiles for assessing status and specifying repairs to the electromechanical cathodes used to make the parts. It is capable of accuracies to a ten-thousandth of an inch. An expanded product line is currently marketed. The gages offer multiple improvements in quality control and significant savings.

Source record↗

NASA NTRS2004

Interaction and Communication of Agents in Networks and Language Complexity Estimates

Knowledge acquisition and sharing are arguably the most critical activities of communicating agents. We report about our on-going project featuring knowledge acquisition and sharing among communicating agents embedded in a network. The applications we target range from hardware robots to virtual entities such as internet agents. Agent experiments can be simulated using a convenient simulation language. We analyzed the complexity of communicating agent simulations using Java and Easel. Scenarios we have studied are listed below. The communication among agents can range from declarative queries to sub-natural language queries. 1) A set of agents monitoring an object are asked to build activity profiles based on exchanging elementary observations; 2) A set of car drivers form a line, where every car is following its predecessor. An unsafe distance cm create a strong wave in the line. Individual agents are asked to incorporate and apply directions how to avoid the wave. 3) A set of micro-vehicles form a grid and are asked to propagate information and concepts to a central server.

Smid, Jan↗

NASA NTRS2010

AlGaN Ultraviolet Detectors for Dual-Band UV Detection

This innovation comprises technology that has the ability to measure at least two ultraviolet (UV) bands using one detector without relying on any external optical filters. This allows users to build a miniature UVA and UVB monitor, as well as to develop compact, multicolor imaging technologies for flame temperature sensing, air-quality control, and terrestrial/counter-camouflage/biosensing applications.

Miko, Laddawan↗

NASA NTRSDate not supplied

AMO-EXPRESS-2.5: Crew Autonomy Onboard the International Space Station

NASA is committed to landing American astronauts, including the first woman and the next man, on the Moon by 2024. Currently, the crew cannot take on all functions performed by the ground today, so the future crews will need more automation to reduce the crew workload for future missions. Of significant importance for these missions is the balance between crew autonomy and vehicle automation. The Advanced Exploration Systems (AES) Autonomous Systems and Operations (ASO) Project has been investigating the ability to evaluate crew self-scheduling and activity monitoring for future space missions. The ASO project designed the Autonomous Mission and Operations- EXpedite the PRocessing of Experiments to Space Station Rack-2.5 (AMO-EXPRESS-2.5) payload to evaluate crew self-scheduling and activity monitoring. The AMO-EXPRESS-2.5 builds on the previous AMO-EXPRESS and AMO-EXPRESS-2.0 demonstrations on ISS. The AMO-EXPRESS-2.5 demonstration goals are to prove crew self-scheduling by planning through diagnosing systems expertise, failure detection, procedure recommendation and situational awareness. This paper will describe the development, test and execution results of the AMO-EXPRESS-2.5 demonstration, and will also outline the future planned development and operational efforts to enable autonomy for future deep space manned missions.

Brooke C. Allen↗

NASA NTRS2022

Drought Monitoring with Drones: A Hundred Fields at a Time

Drought frequency and severity are likely to increase due to global warming. Droughts already have a substantial negative influence on agriculture and the economy and finding ways to reduce their effects could have a monumental impact. Although NASA already has satellites deployed to collect drought data, these satellites are more for global drought indexing than local. To alleviate droughts on a local level, this paper proposes the use of drones to map soil moisture, plant health, and other drought indicators. The proposed drone design is a fixed-wing UAV equipped with a hyperspectral camera, a LiDAR sensor, and an array of weather sensors. These tools will permit it to reliably capture the necessary data to enhance suggestions on improving drought management practices. The collected data from the drones will be deployable in many ways, including for agricultural and non-agricultural applications. The hyperspectral camera has applications in monitoring the health of crops within a field to direct relief measures to the crops most in need. Thermal and LiDAR imaging can be deployed for locating leaks, predicting shortages of water bodies, and determining a field’s water needs. To implement a drought-monitoring drone, the recommended steps include building a prototype drone design that is equipped with the outlined instruments. The prototype drone could then be deployed to collect training data to guide a neural network that would provide interpretations and predictions from the data for users. After the prototype design is iterated upon, it will be ready for deployment and inform water management methods to serve the world in our battle against drought.

climate change↗

NASA NTRS2023

Lunar Development and Test Facility Virtual Walkthrough

This is a 3D virtual tour (VR) of the Lunar Development and Test Facility at Johnson Space Center. This tour will allow users to see the different aspects and projects throughout this facility. With clickable walk through circles that allow you to travel through the building along with interactive posters and monitors that give additional information on projects for the specific areas being viewed. The bottom left of the screen contains viewing options for changing positions as desired and bottom right offers a View in VR and a full screen option.

Kristopher Lee↗

NASA NTRSDate not supplied

ASTM International Conference on Additive Manufacturing – 2022

The In-Situ Project: Correlating In-situ monitoring data and Non-Destructive Evaluation (NDE) methods to characterize defect populations in Laser Powder Bed Fusion (L-PBF) material NDE is critical to enable the safe use of additive manufactured (AM) parts in aerospace applications. However, traditional NDE methods are not fully adaptable to complex AM geometries to appropriately screen for critical defects, and L-PBF processes inherently generate defects. In-situ monitoring techniques can give information about the quality of the build process and indicate process variations that could potentially create defects. Proven, causal correlations between in-situ monitoring indications and resulting defects are needed to inform about the final quality of the part. Thus, the development of a new approach is necessary. NASA started a two-phase study that would investigate techniques for characterizing defect populations in L-PBF material, first in material with induced defects, then in a nominal L-PBF process, by correlating in-situ, NDE, and serial sectioning data. Objectives also include the evaluation of seeded defect methodologies for realistic defect creation, creating a baseline of defect populations in a Qualified Material Process (QMP), characterizing the effect of heat treatment, and correlating defect populations with tensile and fatigue properties. By comparing computed tomography images, in-situ monitoring images, and metallography images, the team has been able to draw preliminary conclusions. They include a better understanding of the limitation of the NDE tools, learning about the “healing” of the samples observed during layer building and a comparison study on different laser power variation samples. Those preliminary conclusions will help dictate the follow-up work that will be presented at the conference.

additive manufacturing↗

DOE OSTI2024

Evaluation of In-Situ AM Process Monitoring Techniques and Potential for Detecting Process Anomalies and Undesirable Microstructures

The US Department of Energy’s Advanced Materials and Manufacturing Technologies (AMMT) program is pursuing rapid qualification of new materials for fabrication of nuclear relevant components using advanced manufacturing techniques. Particular interest is placed on code-qualifying stainless steel (SS) 316H processed by laser powder bed fusion (LPBF) additive manufacturing. A paradigm that incorporates data from in-situ sensing during the printing, ex-situ characterization, and advanced artificial intelligence–based models was established under the Transformation Challenge Reactor (TCR) program to develop a pedigree for each fabricated component that could be tracked from the feedstock to the component’s release for application. Under the TCR program, the Peregrine software was developed as a tool for incorporating the vast amounts of in-situ and ex-situ characterization data collected; all data stored on a rapidly growing digital platform. The digital platform allows for users to link site-specific process anomalies to the macro- and microstructure. The platform will eventually be able to predict component performance, which will be crucial to qualifying materials and components in risk-averse industries such as those supporting and building nuclear reactors. Current in-situ process monitoring techniques that are already integrated with software like Peregrine are advantageous for identifying process anomalies including powder spatter, component edge swelling, recoating-build interactions, and so on. However, additional data are required to fully predict the resulting microstructures needed for identifying relationships to component performance. The rapid cooling rates observed in LPBF are some of the highest of any bulk manufacturing process, resulting in heterogenous microstructures and typically causing anisotropy in mechanical properties. Moreover, evolved residual thermal stresses are high, which can cause severe defects such as delamination or cracking. Therefore, other in-situ monitoring methods are warranted for exploration to measure and map the thermal history, and potentially the stress state, of each build. This report summarizes different in-situ monitoring strategies proposed for LPBF with a focus on the more developed sensor systems. Novel capabilities for measuring melt pool temperatures are also addressed to better inform modeling efforts.

36 MATERIALS SCIENCE↗