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DOE OSTI2021

Lensless X-Ray Nanoimaging: Revolutions and opportunities

Lensless x-ray nanoimaging is providing 3D views of a wide range of materials with a spatial resolution better than 20 nanometers. These advances are enabled in part by dramatic gains in coherent x-ray flux, but they also rely on advances in signal processing to obtain images from coherent diffraction data. Here, we outline the various imaging approaches, the associated reconstruction methods, and highlight opportunities for future advances.

42 ENGINEERING↗

DOE OSTI2023

Data Archive and Portal (DAP) Platform for Solid Phase Processing Technologies

The scale and speed of data generated by modern scientific experiments have constantly challenged the research community to store, curate, manage and optimally use it to drive scientific discoveries. In this work, we have developed a data archive and portal (DAP) platform including analytics capabilities to collect, curate, and manage data and metadata stream for solid phase processing (SPP) techniques. We successfully hosted around ~347K files of data related to processing parameters, microscopic images, and spectroscopic data related to solid phase processing. The DAP platform for SPP will establish an enduring capability to support machine learning and grow collaboration at the intersection of materials science and data science.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Simulation tools for atom probe tomography: A path for diagnosis and treatment of image degradation

The ideal picture of a near-perfect 3D microscope often presented regarding Atom Probe Tomography faces several issues. These issues degrade the metrological performance of the instrument and find their roots in the phenomena acting at the atomic to the mesoscopic level in the vicinity of the surface of a field emitter. From the field evaporation process at the atomic scale, to the macroscopic scale of the instrument, the path to model the imaging process and to develop more accurate and reliable reconstruction algorithms is not a single lane road. This paper focused on the numerical methods used to understand, treat, and potentially heal imaging issues commonly affecting the data in atom probe experiments. A lot of room for improvement exists in solving accuracy problems observed in complex materials by means of purely electrostatic models describing the image formation in a classical approach. Looking at the sample at the atomic scale, the phenomena perturbing the imaging process are subtle. An examination of atomic scale modifications of the sample surface in the presence of a high surface electric field is therefore mandatory. Atomic scale molecular dynamic models integrating the influence of the high surface electric are being developed with this aim. It is also demonstrated that the complex behavior of atoms and molecules in high fields, and consequences on collected data, can be understood through the use of accurate ab-initio models modified to include the impact of the extreme surface electric field.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

DOE OSTI2019

High-speed Synchrotron X-ray Imaging of Laser Powder Bed Fusion Process

In additive manufacturing (AM) processes, materials are selectively added in layer-wise fashion to build three-dimensional objects. This approach provides several advantages over conventional manufacturing, including the ability to manufacture complex parts, design flexibility, shorter lead times, reduced inventory of spares, and on-demand manufacturing [1]. With these advantages, applications of AM are increasing rapidly in the medical, aerospace, automobile, and defense industries [2, 3]. Currently, laser powder bed fusion (LPBF) is the most extensively used AM technique for manufacturing metal parts. In a typical LPBF process, a high-power laser beam is scanned across a thin layer of powder, melting and subsequently fusing it to the previous layer. Highly transient interactions between the laser, powder particles, and the bottom layer lead to defects in the AM materials. These defects include porosity, residual stresses, surface roughness, and undesirable microstructures [1, 4]. Additionally, several in situ techniques have been developed to capture these interactions in real time, including high-speed visible light and infra-red imaging [5]. However these techniques are limited to surface observations. Most of the important phenomena that govern the quality of the AM parts, such as dynamics of the vapor depression and melt pool, occur sub-surface and hence cannot be captured using traditional optical techniques. Recently, a synchrotron-based high-speed X-ray imaging technique has been developed to record the sub-surface dynamics of metallic materials during the LPBF process. The unprecedented spatial and temporal resolutions afforded by the synchrotron sources allow direct observation of many important phenomena in AM for the first time [6–9]. Further, high-speed X-ray diffraction and optical imaging techniques are also being applied to capture the crystallographic and thermal information of the material, respectively, as they undergo melting, solidification, and cooling [6, 9]. In this contribution, we introduce the recent developments at the Advanced Photon Source (APS) for in situ and operando study of LPBF processes.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2016

Quantifying element incorporation in multispecies biofilms using nanoscale secondary ion mass spectrometry image analysis

Elucidating nutrient exchange in microbial communities is an important step in understanding the relationships between microbial systems and global biogeochemical cycles, but these communities are complex and the interspecies interactions that occur within them are not well understood. Phototrophic consortia are useful and relevant experimental systems to investigate such interactions as they are not only prevalent in the environment, but some are cultivable in vitro and amenable to controlled scientific experimentation. Nanoscale secondary ion mass spectrometry (NanoSIMS) is a powerful, high spatial resolution tool capable of visualizing the metabolic activities of single cells within a biofilm, but quantitative analysis of the resulting data has typically been a manual process, resulting in a task that is both laborious and susceptible to human error. In this work, the authors describe the creation and application of a semiautomated image-processing pipeline that can analyze NanoSIMS-generated data, applied to phototrophic biofilms as an example. The tool employs an image analysis process, which includes both elemental and morphological segmentation, producing a final segmented image that allows for discrimination between autotrophic and heterotrophic biomass, the detection of individual cyanobacterial filaments and heterotrophic cells, the quantification of isotopic incorporation of individual heterotrophic cells, and calculation of relevant population statistics. The authors demonstrate the functionality of the tool by using it to analyze the uptake of 15 N provided as either nitrate or ammonium through the unicyanobacterial consortium UCC-O and imaged via NanoSIMS. The authors found that the degree of 15N incorporation by individual cells was highly variable when labeled with 15 NH 4 + , but much more even when biofilms were labeled with 15 NO 3 – . In the 15 NH 4 + -amended biofilms, the heterotrophic distribution of 15 N incorporation was highly skewed, with a large population showing moderate 15 N incorporation and a small number of organisms displaying very high 15 N uptake. The results showed that analysis of NanoSIMS data can be performed in a way that allows for quantitation of the elemental uptake of individual cells, a technique necessary for advancing research into the metabolic networks that exist within biofilms with statistical analyses that are supported by automated, user-friendly processes.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2021

Process Control Plan to Monitor Acceptable Levels of Flux and other residues

IPC J-STD –001G, Amendment 1 requires that the assembler have a sampling plan to assure that the process remains in control once qualified and validated. It is well documented that electrochemical failures occur at component sites where flux residues are not fully activated. It is also well known that specific components have a higher risk of electrochemical failure. Selecting a control plan that monitors the process and its performance on challenging components provides assurance that the process maintains control once established during process qualification. The test board used to qualify the process establishes an upper and lower spec limit for each of the component types on the test board. Surface Insulation Resistance upper and lower control limits, using challenging components that are representative of production hardware, represent a golden process condition. The golden image is a measure of process deviations that represents the performance of a resistance curve within a specific period. The objective is to judge whether the process in or out of control.

42 ENGINEERING↗

DOE OSTI2020

Nuclear Canister Corrosion Detection

The software titled "nccd" is used for running residual neural networks (ResNets) on images of nuclear canisters. The software provides only the code for the implementation (based on the fastai library), but it does not share the image data. The compute code allows the use of residual nets (and more generally of other deep learning models) for classifying images from nuclear canisters as corroded. or intact. An image is considered to be corroded if it contains pitting or stress corrosion cracks. The code trains ResNets on image tiles extracted from original images from nuclear canisters, and then implements a classification rule, which can be applied to a validation set to decide if each original image is corroded or intact. The software automates the process of using images taken from nuclear canisters to detect corrosion. It provides also scope for future research directions on the basis of the existing research and code.

Papamarkou, Theodore↗

DOE OSTI2022

Optimization of WAAM Process to Produce AUSC Components with Increased Service Life

Additive manufacturing has the potential to revolutionize industrial hardware and unlock efficiency gains through the fabrication of geometries and architectures not possible by conventional processing. Wire Arc Additive manufacturing (WAAM) process is a class of directed energy deposition process enabling higher build rate and allowing custom wire feedstock allowing spatial variation of microstructure. The larger spot size and lower speed creates a larger melt pool, reducing residual stress and often time creating directional/columnar microstructure for Ni-superalloy. The use of flexible platform provides freedom in deposition strategy, which can accommodate complex substrates, including feature addition onto existing structures, non-flat layers, and repair methods. However, the certification of the final component needs to match the strength requirement. Hence, the quality of the component produced is stringently monitored to avoid buildup of residual stress, cracks, porosity and to reduce detrimental segregated phases commonly observed during alloy solidification. Simulation plays a huge role in predicting the melt pool dimension and can be used to optimize the process parameter. Similar development is also required to perform physics-based modeling of microstructural development in WAAM that can predict the microstructural features during solidification and can be used to optimize the process more effectively. To move toward this goal, Raytheon Technologies Research Center together with Siemens worked to create a set of computational tools to control the process parameters, enable on-line measurements and acquisition with feedback to the optimized process parameters, and eventually track material evolution through each step of the additive process. Computational fluid dynamics is used for accurate prediction and calibration of the thermal field during WAAM process. and phase field models for microstructure evolution as a function of processing parameters to establish a connection between additive parameters and the final microstructure. Here we report cellular automata (CA) model development to predict the dendritic microstructure evolution with surface and bulk nuclei for single track and multiple layers. The CA model was developed to account for secondary element addition and predict segregation, local melting, and latent heat release as well as prediction of Euler angles from orientation information and validated against experiments. This framework was utilized to tailor spatially-varying composition in a part by appropriately controlling the microstructure evolution during the additive process. Functionally graded Haynes 282 alloy with high Cr content at the surface was tested for oxidation and mechanical properties. An advanced physics-based reaction-diffusion model predicting the simultaneous creation of chromium oxide and alumina is developed and validated to extend life expectancy of the WAAM manufactured high temperature part. A machine-learning data-driven framework establishing the process-structure relationship from a dataset of real microstructure images and corresponding process history data has been developed and implemented in the NX Siemens design system. The digital twin configuration along with the tool path generation enabled prediction of WAAM component buildup time and the techno-economic analysis provided a favorable option for all 4 cases with 15-40% cost reduction.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2026

202508 HAIIC IR Images with Attitude Data at BNF

This campaign aims to collect infrared imagery using a custom data acquisition system to improve and validate a previously developed attitude estimation algorithm, with a focus on ensuring reliable performance at higher altitudes. The system integrates a Boson+320 infrared camera, a VN-200 IMU for recording attitude data synchronized with image acquisition, and a Raspberry Pi 4B+ for onboard processing and storage. Image orientation was controlled using a Gremsy T7 gimbal. The primary dataset spans roll angles from −40° to 40° and pitch angles from −20° to 40°, sampled at 1° increments. Additional, smaller datasets were also collected at 2.5° angular intervals.

Boson+320↗

DOE OSTI2021

Infrared intrusion detection system (IRIDS)

A system and method for intrusion detection includes an imager directed towards an object in an interior space. The imager is in data communication with a computer. The computer is arranged to process digital three-dimensional image data received from the imager and programmed to execute a change detection algorithm in response to the processed three-dimensional data to determine movement of the object. The computer generates an alarm output in response to detecting movement of the object above a predetermined threshold. The method includes providing an imager directed towards an object in an interior space; receiving Time of Flight signals by the imager; processing digital three-dimensional image data received from the imager; and executing a change detection algorithm in response to the processed three-dimensional data to determine movement of the object.

Russell, John L.↗

DOE OSTI2021

Identification and correction of temporal and spatial distortions in scanning transmission electron microscopy

Scanning transmission electron microscopy (STEM) has become the technique of choice for quantitative characterization of atomic structure of materials, where the minute displacements of atomic columns from high-symmetry positions can be used to map strain, polarization, octahedra tilts, and other physical and chemical order parameter fields. The latter can be used as inputs into mesoscopic and atomistic models, providing insight into the correlative relationships and generative physics of materials on the atomic level. However, these quantitative applications of STEM necessitate understanding the microscope induced image distortions and developing the pathways to compensate them both as part of a rapid calibration procedure for in situ imaging, and the post-experimental data analysis stage. Here, we explore the spatiotemporal structure of the microscopic distortions in STEM using multivariate analysis of the atomic trajectories in the image stacks. Based on the behavior of principal component analysis (PCA), we develop the Gaussian process (GP)-based regression method for quantification of the distortion function. The limitations of such an approach and possible strategies for implementation as a part of in-line data acquisition in STEM are discussed. Here, the analysis workflow is summarized in a Jupyter notebook that can be used to retrace the analysis and analyze the reader's data.

36 MATERIALS SCIENCE↗

DOE OSTI2016

A new data processing technique for Rayleigh-Taylor instability growth experiments

Typical face-on experiments for Rayleigh-Taylor instability study involve the time-resolved radiography of an accelerated foil with line-of-sight of the radiography along the direction of motion. The usual method which derives perturbation amplitudes from the face-on images reverses the actual image transmission procedure, so the obtained results will have a large error in the case of large optical depth. In order to improve the accuracy of data processing, a new data processing technique has been developed to process the face-on images. This technique based on convolution theorem, refined solutions of optical depth can be achieved by solving equations. Furthermore, we discuss both techniques for image processing, including the influence of modulation transfer function of imaging system and the backlighter spatial profile. Besides, we use the two methods to the process the experimental results in Shenguang-II laser facility and the comparison shows that the new method effectively improve the accuracy of data processing.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2022

Layer-wise Imaging Dataset from Powder Bed Additive Manufacturing Processes for Machine Learning Applications (Peregrine v2022-10)

36 MATERIALS SCIENCE↗

DOE OSTI2023

Layer-wise Imaging Dataset from Powder Bed Additive Manufacturing Processes for Machine Learning Applications (Peregrine v2022-10.1)

This release consists of six datasets which together include multi-modal layer-wise powder bed images from two different powder bed printing technologies. These datasets are designed primarily to facilitate the development and testing of new computer vision and machine learning based anomaly and defect detection algorithms. The authors provide both training data with corresponding ground truth pixel masks and evaluation data with corresponding baseline prediction pixel masks made by a trained neural network. The laser powder bed fusion (L-PBF) datasets are sourced from EOS M290 and AddUp FormUp 350 printers and the binder jet (BJ) dataset is sourced from an ExOne M-Flex printer. The materials represented in these datasets include 17-4 PH Stainless Steel, GammaPrint-700, Inconel 718, Maraging Steel, and H13 Steel. The sensor imaging modalities represented include visible-light (VL), temporally-integrated (i.e., long duration exposure) near-infrared (TI-NIR), and wide-band infrared (IR). To download the dataset: (1) Create a Globus account. (2) Create a Globus Endpoint on your computer. (3) Transfer the dataset from the OLCF DOI-DOWNLOADS Collection to your Collection. Common troubleshooting steps: (a) Confirm that the transfer is going from OLCF DOI-DOWNLOADS to your Collection. (b) Create an exception for Globus in your antivirus software so that it can create an Endpoint. (c) Manually create a Globus access directory (where the data will be downloaded) by going to the Preferences > Access tab.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Real-Time Data Acquisition and Processing System for MHz Repetition Rate Image Sensors

An electro-optic detector is one of the diagnostic setups used in particle accelerators. It employs an electro-optic crystal to encode the longitudinal beam charge profile in the spectrum of a light pulse. The charge distribution is then reconstructed using data captured by a fast spectrometer. The measurement repetition rate should match or exceed the machine bunching frequency, which is often in the range of several MHz. A high-speed optical line detector (HOLD) is a linear camera designed for easy integration with scientific experiments. The use of modern FPGA circuits helps in the efficient collection and processing of data. The solution is based on Xilinx 7-Series FPGA circuits and implements a custom latency-optimized architecture utilizing the AXI4 family of interfaces. HOLD is one of the fastest line cameras in the world. Thanks to its hardware architecture and a powerful KALYPSO sensor from KIT, it outperforms the fastest comparable commercial devices.

MicroTCA↗

DOE OSTI2018

Hyperspectral Raman imaging using a spatial heterodyne spectrometer (SHS)

Savannah River National Laboratory, and the larger community, has limited chemical-specific imaging capabilities, which would be beneficial for remote detection of threat chemicals or use in inaccessible and harsh environments, as well as in-line process monitoring. Chemical imaging technology would support multiple directorates through stand-off detection of chemicals (National Security), and imaging of chemical distributions in a process (Nuclear Materials Management, Clean Energy) and in waste tanks (Environmental Stewardship). Chemical-specific imaging is underdeveloped due to issues of sensitivity, stable alignment and calibration, and ease of operation associated with most optical instruments. The project objective is to develop a novel, rugged, highly sensitive spectrometer to support real-time, chemically specific imaging using hyperspectral Raman spectroscopy. Raman spectroscopic analysis will provide chemical specificity and using a spatial heterodyne spectrometer (SHS) will increase the sensitivity due to the high light throughput design. The SHS design does not require moving parts allowing for a very stable system, reducing alignment and calibration issues. The instrument will be assembled and initially applied to Raman gas detection of the Saltstone disposal unit headspace gas concentrations. Raman gas analysis is the most impacted by sensitivity issues and will be used to demonstrate the increased light collection capability of the SHS over a conventional dispersive spectrometer. The system will be later modified to image spectral information in a spatial domain to provide information on the spatial distribution of a sample scene.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2018

Revealing particle-scale powder spreading dynamics in powder-bed-based additive manufacturing process by high-speed x-ray imaging

Powder spreading is a key step in the powder-bed-based additive manufacturing process, which determines the quality of the powder bed and, consequently, affects the quality of the manufactured part. However, powder spreading behavior under additive manufacturing condition is still not clear, largely because of the lack of particle-scale experimental study. Here, we studied particle-scale powder dynamics during the powder spreading process by using in-situ high-speed high-energy x-ray imaging. Evolution of the repose angle, slope surface speed, slope surface roughness, and the dynamics of powder clusters at the powder front were revealed and quantified. Interactions of the individual metal powders, with boundaries (substrate and container wall), were characterized, and coefficients of friction between the powders and boundaries were calculated. The effects of particle size on powder flow dynamics were revealed. Here, the particle scale powder spreading dynamics, reported here, are important for a thorough understanding of powder spreading behavior in the powder-bed-based additive manufacturing process, and are critical to the development and validation of models that can more accurately predict powder spreading behavior.

42 ENGINEERING↗

DOE OSTI2018

Readout models for BaFBr 0.85 I 0.15 :Eu image plates

The linearity of the photostimulated luminescence process makes repeated image-plate scanning a viable technique to extract more dynamic range. In order to obtain a response estimate, two semi-empirical models for the readout fading of an image plate are introduced; they relate the depth distribution of activated photostimulated luminescence centers within an image plate to the recorded signal. Model parameters are estimated from image-plate scan series with BAS-MS image plates and the Typhoon FLA 7000 scanner for the hard x-ray image-plate diagnostic over a collection of experiments providing x-ray energy spectra whose approximate shape is a double exponential.

47 OTHER INSTRUMENTATION↗