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DOE OSTI2024

Fabrication and Testing of a Stainless Steel Quartz Coaxial Cable Structure for High Temperature Measurement

This paper presents a stainless-steel quartz coaxial cable structure for distributed sensing of high temperatures. The coaxial cable sensor uses stainless steel as the inner and outer conductors and quartz as the insulator in order to achieve mechanical strength and temperature resilience. Girdle-shaped reflectors are fabricated on the quartz tubing by CNC grinding and CO 2 laser resurfacing. The sensor operates by measuring the temperature dependent change in the effective electromagnetic length between the two adjacent reflectors on the quartz tubing. A retaining collar is fabricated at the tip of the quartz tubing by 3D printing and laser resurfacing to secure the connection between the sensor and the signal cable. The prototype sensor was tested for high temperature measurements up to 600°C, and the performance characteristics of the sensor such as sensitivity, resolution uncertainty, repeatability, and stability were estimated based on the test results.

Jiao, Xinyu↗

DOE OSTI2024

Distributed Magnetic Field and Temperature Monitoring for Superconducting Radio Frequency Cavities

The overall objective of the proposed Phase I program was to design, construct and demonstrate a fiber optic sensing system capable of providing temperature and magnetic field measurements with an enhanced spatial resolution that can be implemented over a large surface area (cryomodules) to survey superconducting radio frequency cavities and magnets. A magnetic field sensor capable of detecting fluxes on the order of 1 μT is required to detect the distribution of trapped flux on the cavity surface. A unique distributed magnetic field sensor was successfully designed and constructed to demonstrate the detection of magnetic fluxes less than 500 nT. The sensor leveraged the ultra-high sensitivity of Sentek’s picoDAS to measure the magnetostriction induced vibrations in a commercially available Metglas 2605 SC ribbon that was in physical contact with sensing fiber. Static magnetic fields were detected by applying an alternating current a copper wire proximate to the Metglas 2605SC ribbon to create an AC bias magnetic field. In an alternative approach, an AC bias magnetic field was applied to a special magnetic field sensing fiber with Metglas 2605SC cladding successfully detect a magnetic field flux of a 3 μT. Exhaustive testing was performed to characterize the dependency of sensor response on the direction of the applied magnetic field. Although the special sensing fiber based magnetic field sensor did not exhibit an observable dependence on the direction of the magnetic field, the Metglas 2605SC ribbon sensor exhibited a clear directional dependence. A wide variety of polymer materials were evaluated to enhance the temperature response of an FBG based sensor at cryogenic temperatures. The processing and performance challenges provided the motivation to develop a new simple cryogenic temperature sensor that uses a commercially available fiber optic splice protector. The EVA hot melt tube that becomes adhered to the optical fiber and the polyolefin outer tube that shrinks upon heating in the fusion splicer heater provide the high thermal expansion coefficient necessary to impart a significant strain on the FBG when exposed to cryogenic temperatures. The temperature sensitivity (Δ𝜆𝐵𝑟𝑎𝑔𝑔~ 62 𝑝𝑝𝑚/℃) of the FBG-based sensor was on par with the best reported to date. The simple design, use of readily available cost-effective materials, and well-established processing techniques lends this approach to the creation of hundreds to thousands of temperature sensors on one single optical fiber length. The inherently small form factor also allows for co-location with the distributed magnetic field sensor. In preparation for field testing of the prototype sensing system at the Jefferson Labs in potential Phase II program, several different cable designs were evaluated to package the sensors. The preliminary successful demonstration of fully functional sensing cables provides the foundation for subsequent development efforts to advance the Technology Readiness Level of the technology. The technical feasibility of the proposed approach was successfully demonstrated in this Phase I effort.

43 PARTICLE ACCELERATORS↗

DOE OSTI2024

Monitoring of ground water table depth and soil moisture at the Point Reyes field site

Ground water table (GWT) depth and soil moisture (SM) have been monitored at several locations at the Point Reyes field site (Californian coastal grassland) from 2021 to 2024. Monitoring is still on-going and data may be added to this archive at later time. The SM data have been acquired using Teros 12 Meter soil moisture sensors placed at 10, 30, 60 and 90 cm depth at 5 locations along a small hillslope. These sensors also collect soil temperature and bulk conductance. In addition, some collocated sensors provide pore pressure and Photochemical Reflectance Index (PRI). The GWT depth has been inferred from various type of Onset pressure transducers. The pressure measurements have been corrected for atmospheric pressure variations and sensor position relative to the ground surface to infer GWT depth, as well as with RTK GPS data to infer GWT elevation. The GWT data have been acquired at 5 distinct locations from 2020 to 2024 with the sensors placed at about 4 m depth. In addition, GWT data has been acquired for the 2023-2024 period with sensors located in 1 m deep shallow wells installed near each deeper well. This data is intended to evaluate possibly different dynamic in shallow (perched) and deep aquifer. The datasets are all provided in csv format. Please note that the interpretation of the GWT data needs to be done with consideration of environmental and well characteristics at the site and uncertainty in various variables. For more information on GWT and SM data, please contact the author.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2025

Improving Stability of an Optical Fiber pH Sensor with a Calcined Polyethylenimine-Coating at High Pressures and Temperatures

With an increased interest in subsurface gas storage technology for various energy applications, monitoring wellbore structural stability and subsurface geochemistry has become more pressing, and pH is a key parameter to measure. As high pressure and elevated temperatures in subsurface conditions are comparatively harsh relative to that expected for most standard pH sensor designs, any pH monitoring hardware must be designed for extended exposure to high pressures and temperatures. We previously reported that an optical fiber pH sensor functionalized with a calcined polyethylenimine coating had shown some promise as a high temperature and pressure pH sensor but with some drifting when operating for longer than 8 hours. In this paper, we investigated the coating composition and potential cause of the drifting and improved the stability of the prepared coating to minimize sensor drift under simulated wellbore conditions. Scanning electron microscopy (SEM) had previously shown moderate cracking at high pressures over short tests. By applying X-ray photoelectron spectroscopy (XPS) to characterize the sensor coating before and after one week of testing in an H2/CH4 gas blend at 80 °C and 900 psi, a compositional change in the coating was observable, which may indicate susceptibility to alteration by subsurface gas storage conditions. Non-reducing (CH4, N2) environments were also tested, and confirmed that both temperature and pressure were also contributing to the drift.

energy infrastructure↗

DOE OSTI2025

Improving Stability of an Optical Fiber pH Sensor with a Calcined Polyethylenimine-Coating at High Pressures and Temperatures

With an increased interest in subsurface gas storage technology for various energy applications, monitoring wellbore structural stability and subsurface geochemistry has become more pressing, and pH is a key parameter to measure. As high pressure and elevated temperatures in subsurface conditions are comparatively harsh relative to that expected for most standard pH sensor designs, any pH monitoring hardware must be designed for extended exposure to high pressures and temperatures. We previously reported that an optical fiber pH sensor functionalized with a calcined polyethylenimine coating had shown some promise as a high temperature and pressure pH sensor but with some drifting when operating for longer than 8 hours. In this paper, we investigated the coating composition and potential cause of the drifting and improved the stability of the prepared coating to minimize sensor drift under simulated wellbore conditions. Scanning electron microscopy (SEM) had previously shown moderate cracking at high pressures over short tests. By applying X-ray photoelectron spectroscopy (XPS) to characterize the sensor coating before and after one week of testing in an H2/CH4 gas blend at 80°C and 900 psi, a compositional change in the coating was observable, which may indicate susceptibility to alteration by subsurface gas storage conditions. Non-reducing (CH4, N2) environments were also tested, and confirmed that both temperature and pressure were also contributing to the drift.

energy infrastructure↗

DOE OSTI2024

The Influence of Microstructure on TCR for Inkjet-Printed Resistive Temperature Detectors Fabricated Using AgNO 3 /Ethylene-Glycol-Based Inks

This study investigated the influence of microstructure on the performance of Ag inkjet-printed, resistive temperature detectors (RTDs) fabricated using particle-free inks based on a silver nitrate (AgNO 3 ) precursor and ethylene glycol as the ink solvent. Specifically, the temperature coefficient of resistance (TCR) and sensitivity for sensors printed using inks that use monoethylene glycol (mono-EG), diethylene glycol (di-EG), and triethylene glycol (tri-EG) and subjected to a low-pressure argon (Ar) plasma after printing were investigated. Scanning electron microscopy (SEM) confirmed previous findings that microstructure is strongly influenced by the ink solvent, with mono-EG inks producing dense structures, while di- and tri-EG inks produce porous structures, with tri-EG inks yielding the most porous structures. RTD testing revealed that sensors printed using mono-EG ink exhibited the highest TCR (1.7 × 10 -3 /°C), followed by di-EG ink (8.2 × 10 -4 /°C) and tri-EG ink (7.2 × 10 -4 /°C). These findings indicate that porosity exhibits a strong negative influence on TCR. Sensitivity was not strongly influenced by microstructure but rather by the resistance of RTD. The highest sensitivity (0.84 Ω/°C) was observed for an RTD printed using mono-EG ink but not under plasma exposure conditions that yield the highest TCR.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2026

Design and Validation of a Cryogenic Dilatometer

This project focuses on the design and development of a cryogenic dilatometer capable of measuring the thermal expansion of materials at extremely low temperatures. Understanding how materials change dimension with temperature is critical for applications involving cryogenic environments, particularly laminated systems housing superconducting magnets, where small dimensional changes can significantly affect performance and reliability. To address this, a dilatometer system was designed to operate within a liquid nitrogen environment while accurately measuring displacements caused by thermal contraction. The purpose of this device is to determine the coefficient of thermal expansion (CTE) of a material. The design process involved defining functional requirements, developing mechanical and thermal concepts for the measurement apparatus, selecting appropriate materials compatible with cryogenic temperatures, and integrating sensors capable of detecting small dimensional changes. The resulting system aims to provide a practical and repeatable method for evaluating material thermal expansion at cryogenic temperatures, supporting research into composite use in superconducting applications that require accurate characterization of material behavior in low-temperature environments.

Schmitt, Nicholas [Northern Illinois U.]↗

DOE OSTI2025

Machine Learning-Guided Design of Perovskite Oxides for High-Temperature Oxygen Sensing

Presentation slides for 2025 MRS Fall Meeting & Exhibit. Reliable oxygen sensors are vital for high temperature applications including combustion engines, steel production, and petrochemical refining, yet identifying stable, high-performance materials for such environments remain challenge. We apply machine learning (ML) to predict the atmospheric oxygen partial pressure–dependent conductivity of perovskite oxides, combining data from the Materials Project and published datasets.

high temperature gas sensor↗

DOE OSTI2024

PV Modules Temperature Variation and Patterns in Medium and Utility-Scale Floating PV Systems

This paper presents the preliminary results and findings of the four operational Floating PV systems across the USA. At each site, temperature of five PV modules located at North-West, North-East, Middle, South-West, and, South-East have been monitored through the Resistant Temperature Detector (RTD) sensors. Three RTDs were attached to each PV module on the rear-side along the diagonal at top, middle and bottom cells. The preliminary results reveal wide temperature differences among the inter and intra PV modules. Besides this, wave pattern temperatures were observed in a few PV modules. The final results, findings, and, factors responsible will be investigated during the next few months.

array↗

DOE OSTI2024

PV Modules Temperature Variation and Patterns in Medium and Utility-Scale Floating PV Systems

ENGINEERING,SOLAR ENERGY↗

DOE OSTI2025

A temperature-induced hysteretic behavior of resistivity and magnetoresistance of electrodeposited bismuth microbridges for X-ray transition-edge sensor absorbers

This study investigates the temperature-induced hysteretic behavior of resistivity and magnetoresistance in electrodeposited bismuth films, with a focus on their application as absorbers in transition-edge sensors (TESs) for X-ray detection. Through a series of resistivity versus temperature measurements from room temperature to a few Kelvin, we explore the change in the conductive behavior of bismuth electrodeposited on various substrates. Our findings show for the first time both hysteretic and irreversible changes in resistivity as a function of temperature. Further, magnetoresistance measurements reveal notable variations in resistance behavior under different magnetic fields, highlighting the impact of magnetic fields on these films’ electronic transport properties, with an indication of potential weak anti-localization effects at the lowest temperatures. This study not only provides a deeper understanding of bismuth’s conductivity characteristics at low temperatures but also sheds light on the practical implications for developing more effective TESs for synchrotron X-ray facilities.

42 ENGINEERING↗

DOE OSTI2024

Simultaneous measurement of temperature and strain by cascaded fiber Bragg grating-silicon Fabry-Perot interferometer sensor

We report a fiber-optic sensor configuration with a cascaded fiber Bragg grating (FBG) and a silicon Fabry-Perot interferometer (FPI) for simultaneous measurement of temperature and strain. The sensor is composed of a 5 mm FBG on a single mode fiber and a 100μm thick silicon FPI attached to the tip of the optical fiber. The FBG is surface mounted on the host structure, and the FPI tip is suspended. Due to the stress-free, cantilever configuration, the silicon FPI is insensitive to strain, but sensitive to temperature with a sensitivity much higher than the FBG due to the large thermo-optic coefficient of silicon. The sensor is tested from room temperature to 100°C with varying strain up to ∼150με. The silicon FPI provides high temperature sensitivity of 89 pm/°C unaffected by strain. Since the FBG is attached to the host structure, it is affected by both thermal and mechanical strain; the sensitivity of these was experimentally obtained 32 pm/°C and 1.09 pm / με, respectively. Interrogated with a broadband light source and a high-speed spectrometer, the sensor shows temperature and strain resolutions of 1.9 × 10 −3 °C and 0.042 με, respectively. Here, due to the small size, enhanced sensitivity, and high resolution, this cascaded FBG-FPI sensor can be used in applications where accurate measurement of temperature and strain is required.

42 ENGINEERING↗

DOE OSTI2026

Surface Energy Balance System (SEBS) Instrument Handbook

A surface energy balance system (SEBS) has been installed collocated with each deployed eddy correlation flux measurement system (ECOR) after 2010 at the U.S. Department of Energy (DOE) Atmospheric Radiation Measurement (ARM) User Facility Southern Great Plains (SGP) observatory, North Slope of Alaska (NSA) observatory, Eastern North Atlantic (ENA) observatory, and the first, second, and third ARM Mobile Facilities (AMF1, AMF2, AMF3). A SEBS was also deployed at the Tropical Western Pacific (TWP) site, before it was decommissioned. Data from these sites, including the retired TWP, are available in the ARM Data Center. The SEBS consists of upwelling and downwelling solar and infrared radiometers within one net radiometer, a wetness sensor, and soil temperature, soil moisture, and soil heat flow measurements. The SEBS measurements allow the comparison of ECOR sensible and latent heat fluxes with the energy balance determined from the SEBS and provide information on wetting of the sensors for data quality purposes.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2026

Nondestructive Modular Leak Detection in 3D Printed 316L Stainless Steel Pipes via Laser Powder Bed Fusion

This research investigates the leak detection features of 316L Stainless Steel pipe structures manufactured via Laser Powder Bed Fusion (LPBF). This work involves the design of a modular sensor system integrating nondestructive evaluation (NDE) methods, including thermal imaging and ultrasonic frequency detection to detect and characterize leaks in components. This aims to improve leak detection sensitivity within medium-pressure gas systems, during continuous operation without halting flow or introducing safety risks. The system could be adaptable for use on unmanned aerial vehicles (UAVs), enabling remote leak detection in active environments. A custom pneumatic system incorporating temperature and pressure sensors was assembled to detect leaks in LPBF-printed 316L SS tee pipes. Experimental results and simulations confirm the system’s effectiveness in leak detection and material evaluation. This research program also integrated a Python-based image recognition platform based on a metallography and optical microscopy to assess the porosity and complement the leak detection data on the printed structures. This allows a detailed analysis of pore distribution and internal leak paths, which could compromise structural integrity, critical for quality control during manufacturing. Findings suggest that the investigated approach holds potential for enhancing leak detection technologies and adapt them for advanced manufactured parts.

36 MATERIALS SCIENCE↗

DOE OSTI2024

AmeriFlux Measurement Component Instrument Handbook

An AMC system was installed at the Atmospheric Radiation Measurement (ARM) Climate Research Facility’s North Slope Alaska (NSA) Barrow site, also known as NSA C1 at the ARM Data Archive, in August 2012. A second AMC system was installed at the third ARM Mobile Facility deployment at Oliktok Point, also known as NSA M1. This in situ system consists of 12 combination soil temperature and volumetric water content (VWC) reflectometers and one set of upwelling and downwelling PAR sensors, all deployed within the fetch of the Eddy Correlation Flux Measurement System. Soil temperature and VWC sensors placed at two depths (10 and 30 cm below the vegetation layer) at six locations (or microsites) allow soil property inhomogeneity to be monitored across a landscape. The soil VWC and temperature sensors used at NSA C1 are the Campbell Scientific CS650L and the sensors at NSA M1 use the Campbell Scientific CS655. The two sensors are nearly identical in function, and vendor specifications are based on the CS650 unless otherwise stated.

47 OTHER INSTRUMENTATION↗

DOE OSTI2026

Thermal Performance of Neutron Sensor Qualification Device

The neutron sensor qualification device was developed to provide a temperature-controlled environment for neutron sensors and dosimetry, enabling irradiation in a neutron field at the Armed Forces Radiobiology Research Institute (AFRRI) TRIGA reactor facility. The device, constructed from low-activation and low neutron cross-section materials, features a modular tube furnace design with three independently controlled heating zones for controlling axial temperature distribution. Laboratory testing validated the device's thermal performance, including uniform temperature distribution with less than 6°C variation across the central region, a steady-state operational temperature of 350°C achieved in approximately 3 hours, and a cooling time constant of 3.5 hours. External surface temperatures remained safe for handling, with the surrounding aluminum structure remaining at ambient conditions. The results confirm the device’s suitability for neutron sensor qualification experiments, with potential for future operation at higher temperatures and further optimization of performance.

46 - INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AN↗

DOE OSTI2026

Thermal Studies of CMS High-Granularity Calorimeter (HGCAL) Cassettes for the HL-LHC Upgrade

The CMS High Granularity Calorimeter (HGCAL) is a key endcap upgrade for the High-Luminosity LHC, designed to operate in an environment of extreme radiation and high particle rates. Each HGCAL cassette integrates silicon and scintillator modules, front-end ASICs, and a copper cooling plate that provides both mechanical integrity and thermal coupling using two-phase CO₂ cooling. Stable and uniform temperature control is essential to ensure reliable performance of the front-end electronics and to limit radiation-induced leakage currents in the silicon sensors. We present results from thermal characterization studies of pre-series HGCAL cassettes assembled and tested at Fermilab. Embedded RTD/PT1000 temperature sensors were used to measure gradients across copper cooling plates, module layers, and cassette edges under powering conditions representative of operation. The measured thermal behavior demonstrates effective heat transport through the cassette stack and highlights small but systematic variations correlated with geometry and assembly tolerances. These results validate the cooling performance of HGCAL cassettes.

Wang, Jinglu [Northwestern U.]↗

DOE OSTI2024

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↗