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DOE OSTI2025

Embedded Sensing in Additive Manufacturing Metal and Polymer Parts: A Comparative Study of Integration Techniques and Structural Health Monitoring Performance

This study presents a comparative evaluation of post-process sensor integration in additively manufactured (AM) metal and the in-situ process for polymer structures for structural health monitoring (SHM), with an emphasis on embedded sensors. Geometrically identical specimens were fabricated using copper via metal fused filament fabrication (FFF) and PLA via polymer FFF, with piezoelectric transducers (PZTs) inserted into internal cavities to assess the influence of material and placement on sensing fidelity. Mechanical testing under compressive and point loads generated signals that were transformed into time–frequency spectrograms using a Short-Time Fourier Transform (STFT) framework. An engineered RGB representation was developed, combining global amplitude scaling with an amplitude-envelope encoding to enhance contrast and highlight subtle wave features. These spectrograms served as inputs to convolutional neural networks (CNNs) for classification of load conditions and detection of damage-related features. Results showed reliable recognition in both copper and PLA specimens, with CNN classification accuracies exceeding 95%. Embedded PZTs were especially effective in PLA, where signal damping and environmental sensitivity often hinder surface-mounted sensors. This work demonstrates the advantages of embedded sensing in AM structures, particularly when paired with spectrogram-based feature engineering and CNN modeling, advancing real-time SHM for aerospace, energy, and defense applications.

additive manufacturing↗

NASA NTRSDate not supplied

Lunar Excavator Mission Operations using Dynamic Movement Primitives

To support sustainable infrastructure on the Moon, NASA must leverage robots to extract lunar resources for in-situ processing and construction. As part of this effort, NASA is launching the in-situ resource utilization (ISRU) Pilot Excavator later this decade to validate a robotic regolith excavator based on the Regolith Advanced Surface Systems Operations Robot (RASSOR). RASSOR is designed to extract and transport regolith to meet the needs of ISRU architectures. During its mission, Pilot Excavator will be tasked with driving in test patterns to demonstrate the operational concept. One of these tests is a circular trajectory around the lander while avoiding miscellaneous surface hazards such as lunar rocks. To this end, we utilize dynamic movement primitives to represent navigation sequences as primitive trajectories. Here, we introduce a novel obstacle avoidance parameter, which is configured to avoid rocks throughout testing exercises. We demonstrate the effectiveness our method in a newly developed simulation tool called the Simulated Excavation Environment for Lunar Operations (SEELO) using models based on the NASA RASSOR 2.0 excavator. After making key changes to the obstacle avoidance formulation, our results show that the robot is able to safety and robustly navigate the lunar surface with densely populated rock obstacles while retaining the desired circle pattern behavior.

Space Robotics and Automation↗

DOE OSTI2013

Sensor Network Demonstration for In Situ Decommissioning - 13332

Florida International University's (FIU's) Applied Research Center is currently supporting the Department of Energy's (DOE) Environmental Management Office of D and D and Facility Engineering program. FIU is supporting DOE's initiative to improve safety, reduce technical risks, and limit uncertainty within D and D operations by identifying technologies suitable to meet specific facility D and D requirements, assessing the readiness of those technologies for field deployment, and conducting feasibility studies and large scale demonstrations of promising technologies. During FY11, FIU collaborated with Savannah River National Laboratory in the development of an experimental test site for the demonstration of multiple sensor systems for potential use in the in situ decommissioning process. In situ decommissioning is a process in which the above ground portion of a facility is dismantled and removed, and the underground portion is filled with a cementious material such as grout. In such a scenario, the question remains on how to effectively monitor the structural health of the grout (cracking, flexing, and sinking), as well as track possible migration of contaminants within and out of the grouted monolith. The right types of sensors can aid personnel in better understanding the conditions within the entombed structure. Without sensors embedded in and around the monolith, it will be very difficult to estimate structural integrity and contaminant transport. Yet, to fully utilize the appropriate sensors and the provided data, their performance and reliability must be evaluated outside a laboratory setting. To this end, a large scale experimental setup and demonstration was conducted at FIU. In order to evaluate a large suite of sensor systems, FIU personnel designed and purchased a pre-cast concrete open-top cube, which served as a mock-up of an in situ DOE decommissioned facility. The inside of the cube measures 10 ft x 10 ft x 8 ft. In order to ensure that the individual sensors would be immobilized during the grout pouring activities, a set of nine sensor racks were designed. The 270 sensors provided by Idaho National Laboratory (INL), Mississippi State University (MSU), University of Houston (UH), and University of South Carolina (USC) were secured to these racks based on predetermined locations. Once sensor racks were installed inside the test cube, connected and debugged, approximately 32 cubic yards of special grout material was used to entomb the sensors. MSU provided and demonstrated four types of fiber loop ring-down (FLR) sensors for detection of water, temperature, cracks, and movement of fluids. INL provided and demonstrated time differenced 3D electrical resistivity tomography (ERT), advanced tensiometers for moisture content, and thermocouples for temperature measurements. University of Houston provided smart aggregate (SA) sensors, which detect crack severity and water presence. An additional UH sensor system demonstrated was a Fiber Bragg Grating (FBG) fiber optic system measuring strain, presence of water, and temperature. USC provided a system which measured acoustic emissions during cracking, as well as temperature and pH sensors. All systems were connected to a Sensor Remote Access System (SRAS) data networking and collection system designed, developed and provided by FIU. The purpose of SRAS was to collect and allow download of the raw sensor data from all the sensor system, as well as allow upload of the processed data and any analysis reports and graphs. All this information was made available to the research teams via the Deactivation and Decommissioning Knowledge Management and Information Tool (D and D KM-IT). As a current research effort, FIU is performing an energy analysis, and transferring several sensor systems to a Photovoltaic (PV) System to continuously monitor energy consumption parameters and overall power demands. Also, One final component of this research is focusing on developing an integrated data network to capture, log and analyze sensor system data in near real time from a single interface. FIU personnel and DOE Fellows monitored the progress and condition of the sensors for a period of six months. During this time, the sensors recorded data pertaining to strain, compression, temperature, crack detection, moisture presence, fluid mobility, shock resistance, monolith movement, and electrical resistivity. In addition, FIU regularly observed the curing process of the grout and documented the cube condition via the nine racks of sensors. The sensors held up throughout the curing process, withstood the natural elements for six months, and monitored the integrity of the grout. The large scale experiment and demonstration conducted at FIU was the first of its kind to demonstrate the feasibility of state of the art sensors for in situ decommissioning applications. These efforts successfully measured the durability, performance, and precision of the sensors in question as well as monitored and recorded the curing process of the selected grout material under natural environmental conditions. The current energy analysis work is resulting in data on the constraints placed by some of the sensor systems on a power network that requires high reliability and low losses. In addition, a sensor system demonstration has determined that it is feasible to develop an integrated data network where data can be accessed in near real-time from all systems, thereby allowing for larger-scale integrated system testing to be performed. Information collected during the execution of this research project will aid decision makers in the identification of sensors to be used in nuclear facilities selected for in situ decommissioning. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2019

Distributed Wireless Antenna Sensors for Boiler Condition Monitoring

Monitoring the operational conditions of coal-fired boilers is an important task that could bring tremendous benefits, including in-situ process control, real-time health assessment of structural components, improved heat transfer efficiency, reduced downtime, etc. Moreover, in-situ distributed sensing of the boiler conditions would provide large scale in-situ measurement data that will help us gain fundamental understandings of the combustion and heat transfer processes as well as enable the developments of new simulation tools, which could eventually lead to better design and more efficient operation of the boilers. The objectives of this research were to (a) develop wireless passive antenna sensors without electronics; (b) demonstrate multi-modality sensing using a signal antenna sensor; and (c) fabricate the antenna sensor from high-temperature materials. In this project, we have demonstrated that an antenna sensor or sensor array without any electronics can be wirelessly interrogated from a distance. In addition, a low-cost compact wireless sensor interrogator was developed for dynamic interrogation of the passive antenna sensor. We validated that a dual-frequency antenna sensor is capable of simultaneous strain and temperature measurements or temperature and ash accumulation measurements; all parameters are relevant to boiler condition monitoring. By measuring the temperature and ash accumulation height simultaneously, the dielectric constant of the ash as well as its temperature dependency can also be characterized. This capability could lead to potential applications of the antenna sensor for combustion process monitoring based on the ash composition. We also investigated different techniques of fabricating the antenna sensor using high-temperature materials such as alumina substrate and platinum paste and characterized the thermal response of the antenna sensor. A linear relationship between the antenna resonant frequency and the temperature change was validated.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2013

LANL CSSE L2: Case Study of In Situ Data Analysis in ASC Integrated Codes [Slides]

The massive, complex datasets generated by scientific simulations on next-generation computer architectures at extreme scale pose new challenges for data management and scientific understanding. A critical element in meeting these new challenges is in situ data analysis where information is reduced and analyzed as close to the point of generation as possible, for example, at run time or as the data stream to longer term storage. This milestone will demonstrate in situ data analysis in xRAGE, an ASC Eulerian Radiation Hydrodynamics code. We will work with the Eulerian Applications Project to identify target problems that will exercise physics of interest to the program, and we will work closely with users to maximize the achieved usability and productivity improvements. We will investigate enhancements to the in situ process that enable and improve techniques of data reduction and data triage in addition to improving in situ performance by using portable acceleration technology. We will report on their viability and performance in xRAGE or another ASC code. These products will provide ASC IC developers with reference codes and tools that will benefit DSW by advancing the technology for predictive science at extreme scales.

97 MATHEMATICS AND COMPUTING↗

NASA NTRSDate not supplied

Additive Manufacturing Model-Based Process Metrics: Reduced Order Modeling of the Laser Powder Bed Fusion Process

The multi-scale and complex process of printing additively manufactured (AM) parts can have unexpected, but predictable, build conditions that result in material microstructure variability. In this work, we describe a fully parallel reduced order modeling approach that has been developed to evaluate the evolution of AM processes, termed the AM moment measure method. This method couples the known sequence of the AM process with a physically informed nearest neighbors’ calculation to map the conditions of a part-scale build. The result is a map of the build that is derived directly from build files or in-situ process monitoring sensors. The methodology and terminology of the approach will be described, and computed build maps will be calculated and compared for various laser powder bed fusion (LPBF) builds of Ti-6Al-4V. Such comparative results develop understanding of how the sequential process actions can affect the LPBF-AM build quality and microstructure variability.

Laser Powder Bed Fusion↗

DOE OSTI2017

Introducing Weirs: An Abstraction for Next Generation Streaming Workflows

In HPC applications, it is widely understood that in situ systems will play a significant role in next generation systems. The rate that next-generation leadership machines will be able to generate data will exceed the bandwidths of the planned I/O systems, leading to a need for in situ processing of the resulting data to reduce it. There have been a number of techniques proposed for in situ workflow systems; we are concerned here specifically with the needs of publish/subscribe or streaming-based approaches, which allow the in situ system to be composed of completely separate executables running concurrently on the hardware. In this paper we introduce an abstract known as a Weir. A weir is a useful mechanism to control state in a point to point streaming workflow in the absence of a third party publish subscribe system.

97 MATHEMATICS AND COMPUTING↗

NASA NTRS2012

Microwave Extraction of Volatiles for Mars Science and ISRU

The greatest advantage of microwave heating for volatiles extraction is that excavation can be greatly reduced. Surface support operations would be simple consisting of rovers with drilling capability for insertion of microwaves down bore holes to heat at desired depths. The rovers would also provide support to scientific instruments for volatiles analysis and for volatiles collection and storage. The process has the potential for a much lower mass and a less complex system than other in-situ processes. Microwave energy penetrates the surface heating within with subsequent sublimation of water or decomposition of volatile containing minerals. On Mars the volatiles should migrate to the surface to be captured with a cold trap. The water extraction and transport process coupled with atmospheric CO2 collection could readily lead to a propellant production process, H2O + CO2 yields CH4 + O2.

Ethridge, Edwin C.↗

DOE OSTI2011

In Situ Nuclear Characterization Infrastructure

To be able to evolve microstructure with a prescribed in situ process, an effective measurement infrastructure must exist. This interdisciplinary infrastructure needs to be developed in parallel with in situ sensor technology. This paper discusses the essential elements in an effective infrastructure.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2019

PAVE: An In Situ Framework for Scientific Visualization and Machine Learning Coupling

Machine learning (ML) has emerged as a tool for understanding data at scale. However, this new methodology comes at a cost because ML requires the use of even more HPC resources to generate ML algorithms. In addition to the compute resources required to develop ML algorithms, ML does not sidestep one of the biggest challenges on leading-edge HPC systems: the increasing gap between compute performance and I/O bandwidth. This has led to a strong push towards in situ, processing the data as it is generated, strategies to mitigate the I/O bottleneck. Unfortunately, there are no in situ frameworks dedicated to coupling scientific visualization and ML at scale to develop ML algorithms for scientific visualization. To address the ML and in situ visualization gap, we introduce PAVE. PAVE is an in situ framework which addresses the data management needs between visualisation and machine learning tasks. We demonstrate our framework with a case study that accelerates physically-based light rendering, path-tracing, through the use of a conditional Generative Adversarial neural Network (cGAN). PAVE couples the training over path-traced images resulting in a generative model able to produce scene renderings with accurate light transport and global illumination of a quality comparable to offline approaches in a more efficient manner.

Kim, Mark B.↗

DOE OSTI2018

Optimizing Scientist Time through In Situ Visualization and Analysis

In situ processing produces reduced size persistent representations of a simulations state while the simulation is running. The need for in situ visualization and data analysis is often described in terms of supercomputer size and performance in relation to available storage size.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2023

Self-supervised learning of spatiotemporal thermal signatures in additive manufacturing using reduced order physics models and transformers

Microstructure control via additive manufacturing has enormous potential as manufacturers, materials scientists, and designers alike seek to exploit novel fabrication technologies to improve component performance. Recent works have demonstrated the feasibility of producing materials with controlled microstructures across various length scales. However, the experimental approach towards exploring the process-structure space can be laborious and costly. This is particularly true if also considering scan pattern optimization which is well suited for processes such as powder bed fusion electron beam melting. In this work we propose an approach for encoding additive manufacturing layer-wise thermal response signatures using self-supervised representation learning. Thermal simulations from a reduced order model are utilized to estimate the spatiotemporal response during printing. A machine learning framework, using video-transformers, is utilized to efficiently distill spatiotemporal patterns into a compact latent space representation. This latent state representation encodes the relevant physics which is then utilized to establish a data-driven process-structure model for an additively manufactured Ni-based superalloy. In conclusion, the proposed methodology could potentially be used towards in-situ process monitoring, scan pattern experimental design, and component qualification.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2023

Leveraging the digital thread for physics-based prediction of microstructure heterogeneity in additively manufactured parts

A major limitation of additive manufacturing (AM) processes is that local conditions of material deposition frequently lead to unintentional heterogeneities in microstructure and properties within a single component, despite nominally uniform process conditions. Up to now, there has been no way to a priori determine the distribution of these heterogeneities, requiring expensive trial-and-error approaches to fabrication, testing, and characterization. Here, a physics-based framework for creating a digital representation of the laser powder bed fusion (PBF) process is proposed to predict the variation in solidification behavior that leads to heterogeneous microstructures in an as-built part. By leveraging in situ process data stored in the part’s digital thread, the scan path and process parameters were input into a heat transfer model which predicted solidification data at the melt pool scale. A two-step unsupervised clustering algorithm was used to first cluster the local solidification conditions (12.5µm 3 voxels) and then to cluster the regional behavior on the scale of multiple scan passes and print layers (250µm 3 super-voxels). This process was used to identify regions with similar solidification characteristics for multiple locations in a Stainless Steel 316-L component. The corresponding as-built part was sectioned and characterized using electron backscatter diffraction (EBSD). Quantitative analysis of the pole figures confirmed that the predicted regions of heterogeneity in the solidification conditions corresponded with differences in the observed microstructure. In conclusion, this work shows a viable path for estimating the microstructural heterogeneity for additively manufactured parts to either limit microstructural variation throughout a part or to enable functionality-based variation of the microstructure.

36 MATERIALS SCIENCE↗

DOE OSTI2016

Liquid metal alloy ion sources—An alternative for focussed ion beam technology

Today, Focused Ion Beam (FIB) processing is nearly exclusively based on gallium Liquid Metal Ion Sources (LMIS). But, many applications in the μm- or nm range could benefit from ion species other than gallium: local ion implantation, ion beam mixing, ion beam synthesis, or Focused Ion Beam Lithography (IBL). Therefore, Liquid Metal Alloy Ion Sources (LMAIS) represent a promising alternative to expand the remarkable application fields for FIB. Especially, the IBL process shows potential advantages over, e.g., electron beam or other lithography techniques: direct, resistless, and three-dimensional patterning, enabling a simultaneous in-situ process control by cross-sectioning and inspection. Taking additionally into account that the used ion species influences significantly the physical and chemical nature of the resulting nanostructures—in particular, the electrical, optical, magnetic, and mechanic properties leading to a large potential application area which can be tuned by choosing a well suited LMAIS. Nearly half of the elements of the periodic table are recently available in the FIB technology as a result of continuous research in this area during the last forty years. Key features of a LMAIS are long life-time, high brightness, and stable ion current. Recent developments could make these sources feasible for nano patterning issues as an alternative technology more in research than in industry. The authors will review existing LMAIS, LMIS other than Ga, and binary and ternary alloys. These physical properties as well as the fabrication technology and prospective domains for modern FIB applications will similarly be reviewed. Other emerging ion sources will be also presented and their performances discussed.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Pressure-based process monitoring of direct-ink write material extrusion additive manufacturing

As additive manufacturing (AM) has become a reliable method for creating complex and unique hardware rapidly, the quality assurance of printed parts remains a priority. In situ process monitoring offers an approach for performing quality control while simultaneously minimizing post-production inspection. For extrusion printing processes, direct linkages between extrusion pressure fluctuations and print defects can be established by integrating pressure sensors onto the print head. In this work, the sensitivity of process monitoring is tested using engineered spherical defects. Pressure and force sensors located near an ink reservoir and just before the nozzle are shown to assist in identification of air bubbles, changes in height between the print head and build surface, clogs, and particle aggregates with a detection threshold of 60–70% of the nozzle diameter. Visual evidence of printed bead distortion is quantified using optical image analysis and correlated to pressure measurements. Importantly, this methodology provides an ability to monitor the quality of AM parts produced by extrusion printing methods and can be accomplished using commonly available pressure-sensing equipment.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Comparison of ex situ x-ray radiography and in situ monitoring to gain control over defects during laser powder bed fusion

As in any other laser welding technique, creation of pores and defects during laser powder bed fusion can lead to component failure and thus cannot be tolerated. Post-build inspection is required to ensure the printed parts are defects-free. These inspections can take time and are complicated particularly for large parts. A solution is to use in situ process monitoring to detect the creation of defects, which could in turn be corrected during the printing itself. However, the relationship between pore creation and in situ monitoring still needs to be understood. In this work, we use x-ray computed tomography to detect pores and correlate them to pyrometry and high speed thermal imaging signals collected during laser welding.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Comparison of ex situ x-ray radiography and in situ monitoring to gain control over defects during laser powder bed fusion

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗

DOE OSTI2020

Optimizing Sub-Sampled STEM Imaging for Beam Sensitive Materials and Dynamic Processes

The goal of this research is to quantify how sub-sampling and inpainting (broadly classified as methods in Artificial Intelligence) can be used to obtain the highest resolution images under any experimental conditions, and to use this to reproducibly control dynamic in-situ processes in gases and liquids on the nanoscale. As atomic diffusion under non-extreme conditions is typically in the sub-ms time domain, the ability to use this sub-sampling approach to reduce the effect of the electron beam and to speed-up the imaging process represents the optimum combination of spatial and temporal resolution achievable in a conventional microscope. This LDRD funding demonstrated the feasibility of imaging dynamics in complex energy systems using this methodology by establishing the optimum experimental sampling conditions (optimizing the number of pixels, speed, contrast and resolution) for each experiment. For in-situ liquid cell experiments this analysis shows that simply by distributing the same dose and dose rate maximally in space and time, the kinetics for radiolysis products can be modified significantly. The final stage of this work, i.e. the experimental demonstration of its use for nucleation and growth, was severely curtailed by issues with COVID19. However, all the experiments are designed and currently underway, with the goal to complete the final demonstration and publication as soon as safety concerns for laboratory access are met.

36 MATERIALS SCIENCE↗