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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Sensing Modalities Deployed - Acoustic

Acoustic approaches to OLM are based on analyzing changes in various forms of pressure waves propagating in solids, fluids or gases. These pressure waves can vary in frequency content from infrasound (seismic events) to the megahertz region (acoustic emissions). A wide variety of commercially available pressure or stain sensing devices are used to make acoustic measurements. These sensors differ in the transduction mechanism used to convert the pressure or strain signal to an electrical output, the sensitivity, dynamic range, bandwidth, directional characteristics, and physical size. All acoustic sensors must be integrated with signal conditioning electronics to convert the sensors’ analog output to discrete digital signals that can then be further analyzed for OLM. Ultimately, the sensing properties listed above will be a function of the sensor transduction mechanism, the sensor design and the conditioning electronics.

47 OTHER INSTRUMENTATION↗
DOE OSTI2023

Aerosol-Jet Printed Sensors for Environmental, Safety, and Health Monitoring: A Review

An emergent direct-write approach, aerosol-jet printing (AJP), is gaining attention for the deployment of rapid and affordable microadditively manufactured energy-efficient sensors and printed electronics. AJP enables a broad range of ink viscosities (0.001–1 Pa s) for printing diverse materials ranging from ceramics and metals to polymers and biological matter. Reproducible, high-spatial-resolution features (≈10 µm), and wide standoff distances (1–11 mm) between the nozzle and the substrate facilitate conformal printing of complex geometrical designs on nonplanar—e.g., stepped or curved—surfaces. Here this paper aims to provide a comprehensive overview of state-of-the-art AJP-based sensors (e.g., strain and temperature gauges, biosensors, photosensors, humidity and surface acoustic wave sensors, dielectric elastomer actuators, and motion, smoke, and hazardous gas detectors) and to discuss prospective applications. The drive toward cost-effective devices that are smaller, lighter, and better-performing remains a frontier challenge in the field of printed electronics. Consequently, as AJP becomes increasingly utilized in the high-volume manufacturing of miniaturized active and passive sensors, it opens a pathway for facile large-scale fabrication of devices for a wide range of consumer and industrial applications, including transportation, agriculture, infrastructure, aerospace, national defense, and healthcare.

3-dimensional↗
DOE OSTI2026

Correlation of Surface Acoustic Wave (SAW) force myography sensor output with elbow joint torque

Accurate assessment of skeletal muscle forces and net joint torque is essential for preventing fatigue-related injuries, optimizing physical training, and monitoring disease progression in neuromuscular conditions. However, existing joint torque evaluation techniques are hindered by limited portability and high operational costs, confining their use to controlled laboratory or clinical settings. Despite substantial advances in wearable joint torque estimation systems, ongoing challenges such as power constraints, bulky wired setups, and susceptibility to environmental or motion artifacts underscore the urgent need for truly batteryless, wireless solutions deployable in real-world settings. This paper proposes a novel surface acoustic wave (SAW)-based force myography (FMG) system for noninvasive measurement of joint torque, validated against a gold-standard electromechanical dynamometer. The approach uses a single SAW sensor embedded in an armband to detect volumetric biceps brachii changes, with a second-order polynomial mapping sensor output and elbow angle to torque. Seven participants were tested in both isometric (15°–90°) and isokinetic (10°/s and 20°/s) supinated elbow flexion tasks. Under isometric conditions, subject-specific calibration achieved a normalized root-mean-square error (NRMSE) of 13.6% ± 6.0% and R 2 = 0.834 ± 0.180, while a group-level model yielded 14.4% ± 6.8% and 0.808 ± 0.208, respectively. For isokinetic trials, the group model produced an NRMSE of 24.1% ± 6.6% at 10°/s and 24.9% ± 08.9% at 20°/s, highlighting the feasibility of using a single-sensor SAW-FMG setup across different speeds. Because SAW devices support wireless, battery-free operation, the proposed system offers a pathway to portable, real-time monitoring for sports medicine, rehabilitation, and clinical diagnostics.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Localized keyhole pore prediction during laser powder bed fusion via multimodal process monitoring and X-ray radiography

Systematic fault detection and control during laser powder bed fusion (L-PBF) has been a long-standing objective for system manufacturers and researchers in the additive manufacturing (AM) industry. This manuscript investigates a data fusion approach for detection of keyhole porosity formation during laser irradiation of Ti-6Al-4V substrates by concurrent recording of thermally induced optical emission measured using both off-axis and coaxial photodiode sensors, and acoustic emission. Subsurface defect formation was monitored via high-speed synchrotron X-ray imaging at 20,000 frames per second, enabling temporal registration of keyhole pore formation events to the monitoring signals at a resolution of 50 µs. We developed data fusion machine learning (ML) models for localized prediction of keyhole pore formation at various time scales ranging from 0.5 ms to 2 ms. The signal segments were featurized using two independent approaches: (1) power spectral density (PSD) and (2) highly comparative time series analysis (HCTSA) framework. The extracted features from different sensor modalities were fused together to construct a multimodal feature space and sequential feature selection was used to determine the most informative features for training the ML models. The predictive performance was evaluated for three classifying algorithms: Support Vector Machine (SVM), K-Nearest Neighbor (KNN), and Gaussian Naive Bayes (GNB). As a result, pore formation events were predicted with up to 0.95 F1-score, 1.0 recall and 0.94 accuracy. The most heavily weighted features indicate that model performance is chiefly governed by the acoustic monitoring signal, with a secondary contribution from the optical emission sensors.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Sensor fusion of pyrometry and acoustic measurements for localized keyhole pore identification in laser powder bed fusion

We report in-situ process monitoring as an aid to part qualification for laser powder-bed fusion (L-PBF) technology is a topic of increasing interest to the additive manufacturing community. In this work, airborne acoustic and inline pyrometry measurements were recorded simultaneously with the laser position. X-ray radiography imaging was used to spatio-temporally register keyhole pore locations to the pyrometry and acoustic signals, enabling binary labeling of data partitions based on pore formation. These labeled partitions were subsequently featurized using a highly comparative time-series analysis toolbox. Acoustic data was found to be much more effective than the pyrometry data for keyhole pore identification. However, when the information contained in both sensing modalities was combined in a sensor fusion strategy, the error rates of the top performing models were significantly reduced.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Advancing Industry 4.0: Multimodal Sensor Fusion for AI-Based Fault Detection in 3D Printing

Additive manufacturing, particularly fused deposition modeling, is transforming modern production by enabling rapid prototyping and complex part fabrication. However, its layer-by-layer process remains vulnerable to faults such as nozzle clogging, filament runout, and layer misalignment, which compromise print quality and reliability. Traditional inspection methods are costly, time-intensive, and often limited to post-process analysis, making them unsuitable for real-time intervention. In this current study, the authors developed a novel, low-cost, and portable faultdetection system that leverages multimodal sensor fusion and artificial intelligence for real-time monitoring in FDM-based 3D printing. The system integrates acoustic, vibration, and thermal sensing into a non-intrusive architecture, capturing complementary data streams that reflect both mechanical and process-related anomalies. Acoustic and thermal sensors operate in a fully contactless manner, while the vibration sensor requires minimal attachment such that it will not interfere with printer hardware, thereby preserving portability and ease of deployment. The multimodal signals are processed into spectrograms and time-frequency features, which are classified using convolutional neural networks for intelligent fault detection. The proposed system advances Industry 4.0 objectives by offering an affordable, scalable, and practical monitoring solution that improves faultdetection accuracy, reduces waste, and supports sustainable, adaptive manufacturing.

42 ENGINEERING↗
DOE OSTI2021

Laboratory Evaluation of the Thermal Breakout Method for Maximum Horizontal Stress Measurement

Measuring in situ stress is essential for many problems in geomechanics, and the maximum horizontal stress is the most difficult to constrain. We are developing an extension of the breakout method to measure maximum horizontal stress in regions where natural breakouts do not occur. In the novel thermal breakout method, additional compression which leads to breakout development is induced by heating the borehole wall. In the present study, we validated the method experimentally in a true-triaxial apparatus on samples with predrilled boreholes. Two rocks were selected for laboratory testing: high-porosity Berea sandstone and low-porosity Niagaran dolomite. Prior to main true-triaxial tests, we carried out standard testing to characterize the strength, elasticity and thermal properties. The true-triaxial experiments consisted of: (1) room-temperature tests where samples were first loaded mechanically until the breakout formed, and (2) elevated-temperature tests where samples were loaded mechanically within the elastic range with additional compression induced thermally. Breakout initiation was monitored by acoustic emission sensors mounted on the pistons that applied horizontal stresses. Furthermore, the magnitude of induced thermal stress was calculated from temperature measurements around the borehole wall. In both rock types, we created thermally induced breakouts and examined analytical expressions to constrain maximum horizontal stress based on strength, elastic and thermal properties of the rocks.

58 GEOSCIENCES↗
DOE OSTI2022

Engineering Company Recognized for Advanced Use of Lighting Sensors and Controls - Case Study: IMEG Corp, IL

This case study describes the implementation of several emerging lighting techniques at the new Chicago offices of IMEG Corp, an engineering and design consulting firm. IMEG collaborated with Pacific Northwest National Lab as part of a study to better understand the physiological and psychological impacts of advanced lighting strategies on occupant comfort, well-being, and energy savings. The project was recognized as part of DOE's Integrated Lighting Campaign.

integrated lighting, lighting, controls, tunable, ↗
DOE OSTI2024

Evaluation of the Turbine Integrated Mortality Reduction (TIMR SM ) Technology as a Smart Curtailment Approach (Final Summary Report)

Wind energy is a crucial technology for achieving net-zero emissions by 2050. However, the growth and deployment of wind energy in North America have led to the deaths of many bat species due to operating wind turbines. Hundreds of thousands of bats are estimated to die at wind turbines annually in North America. Operational minimization, which includes feathering turbine blades and curtailment, has been documented to reduce bat fatality effectively. Curtailment refers to altering turbine operation based on wind speed, time of year, temperature, sensors, and activity models. However, when turbines are curtailed, they do not generate power, resulting in energy loss and revenue for wind energy facilities. The Electric Power Research Institute (EPRI) funded the development of Turbine Integrated Mortality Reduction (TIM SM ) Technology, which curtails turbine operation when bats are detected. The initial TIMR system research showed promising results, with an 85% reduction in overall bat fatalities and a 91% reduction for the little brown bat. However, these results were based on a single site during one fall season, and it was unclear if similar results could be replicated at other wind energy facilities. This research aimed to validate the TIMR system results from the prior field study at a second site in the U.S., estimate the power production and reduction in bat mortality at turbines with installed TIMR systems relative to blanket curtailment and fully operational turbines, test the TIMR system in two calendar years and during the summer and fall periods, and evaluate the operational and commercial characteristics of the TIMR system for potential wind industry adoption. The study was conducted at a 500.9-MW wind energy facility in southeast Adair County, Iowa. Three experimental treatments were involved in this randomized block design study: TIMR, Curtailment at 5.0 m/s, and Normal Operation. In 2021, three treatments were used at 18 turbines, expanding to four treatments across 36 turbines in 2022. The TIMR system worked as designed throughout the entire study; however, because of unexpected wind turbine operational challenges in 2021, there was not sufficient sample size to evaluate the treatment differences. In 2022, there were significant differences in fatality levels between treatment types and normal operating turbines. Curtailment at 5.0 m/s reduced fatalities by 30.8% compared to normal operations, and TIMR decreased fatalities by 48.6% compared to normal operations. Two different methods were used to evaluate the differences in energy loss for each treatment. The TIMR system resulted in 1.3% to 1.6 % annual energy loss in 2021 and 1.0% to 1.2 % in 2022. The Curtailment at 5.0 m/s resulted in 0.6% to 0.8 % annual energy loss in 2021 and 0.5% to 0.6 % in 2022. The project achieved all the stated objectives and demonstrated that TIMR is an effective technology that balances bat fatality reduction with energy generation. The results will support the deployment of TIMR and other acoustic sensor-based technologies. The research provides valuable insights into the impact of different treatments on fatality rates and energy outputs, contributing to the ongoing efforts to mitigate the environmental impact of wind energy.

17 WIND ENERGY↗
DOE OSTI2023

Self-powered ocean buoy using a disk-type triboelectric nanogenerator with a mechanical frequency regulator

Triboelectric nanogenerator (TENG) systems have been demonstrated to generate power with high density. However, the electrical output power obtained from wave energy harvesting using TENG systems is typically limited to several milliwatts. To address this limitation and support various ocean buoy systems, an efficient method to scale-up TENG systems is required. In this paper, we present a self-powered ocean buoy (SPOB) incorporating a disk-type, soft-contact, mechanical frequency regulator TENG (DSMFR-TENG). The mechanical frequency regulator (MFR) enables the conversion of low-frequency wave energy to high-speed mechanical rotation, facilitating high power generation with the disk-type TENG. Here, the SPOB was tested in a wave tank, reaching a peak power output of 470 mW and an average power output of 130 mW after the MFR released the rotational energy. To further enhance the functionality of the buoy, the DSMFR-TENG and a microcontroller, temperature sensor, and acoustic transmitter were integrated with the SPOB. The acoustic transmitter successfully transmitted signals 7, 23, and 30 times over a one-minute period at wave frequencies of 0.33 Hz, 0.5 Hz, and 1 Hz, respectively, thereby demonstrating the power supply capability of the TENG system for ocean buoys.

42 ENGINEERING↗
DOE OSTI2022

Temperature and Dynamic Strain Measurements Using a Single SAWR Sensor

Dynamic strain sensing is relevant in numerous applications involving structural health monitoring, condition-based maintenance, operation efficiency preservation, and work environment safety. These sensors are particularly critical for high-temperature (HT) harsh-environment (HE) industries such as aerospace, automotive, power plants, and advanced manufacturing. In HT/HE, sensor implementation and measurement present challenges such as maintaining sensor stability, accounting for temperature cross-sensitivity, providing HT attachment, and packaging of the sensors and system. Surface acoustic wave resonator (SAWR) sensors can address these needs and offer additional benefits such as compact size and wireless interrogation capability. The SAWR sensitivity to dynamic strain is temperature dependent, making it necessary to measure the sensor temperature in order to use the correct dynamic strain calibration curve. In this work, a method for determining the temperature, dynamic strain magnitude, and dynamic strain spectral components using a single SAWR sensor is presented. Here, the established technique for determining operational temperature and dynamic strain magnitude/spectral components using only one SAWR simplifies the sensor measurement system, thus being very attractive for HT /HE applications.

47 OTHER INSTRUMENTATION↗
DOE OSTI2024

Detecting fractures and monitoring hydraulic fracturing processes at the first EGS Collab testbed using borehole DAS ambient noise

Enhanced geothermal systems (EGS) require cost-effective monitoring of fracture networks. We validate the capability of using borehole distributed acoustic sensing (DAS) ambient noise for fracture monitoring using core photos and core logs. The EGS Collab project has conducted 10 m scale field experiments of hydraulic fracture stimulation using 50–60 m deep experimental wells at the Sanford Underground Research Facility (SURF) in Lead, South Dakota. The first EGS Collab testbed is located at 1616.67 m (4850 ft) depth at SURF and consists of one injection well, one production well, and six monitoring wells. All wells are drilled subhorizontally from an access tunnel called a drift. The project uses a single continuous fiber-optic cable installed sequentially in the six monitoring wells to record DAS data for monitoring hydraulic fracturing during stimulation. We analyze 60 s time records of the borehole DAS ambient noise data and compute the noise root-mean-square (rms) amplitude on each channel (points along the fiber cable) to obtain DAS ambient noise rms amplitude depth profiles along the monitoring wellbore. Our noise rms amplitude profiles indicate amplitude peaks at distinct depths. We compare the DAS noise rms amplitude profiles with borehole core photos and core logs and find that the DAS noise rms amplitude peaks correspond to the locations of fractures or lithologic changes indicated in the core photos or core logs. We then compute the hourly DAS noise rms amplitude profiles in two monitoring wells during three stimulation cycles in 72 h and find that the DAS noise rms amplitude profiles vary with time, indicating the fracture opening/growth or closing during the hydraulic stimulation. Our results demonstrate that borehole DAS passive ambient noise can be used to detect fractures and monitor fracturing processes in EGS reservoirs.

58 GEOSCIENCES↗
DOE OSTI2022

Data Report: TurboWave I and II Data Release

The TurboWave I and II infrasound campaigns were conducted to examine short term variability in acoustic propagation at local and regional distances. The tests were conducted in nearly co-located regions at the Energetic Materials Research and Testing Center in Socorro, NM between 2019 and 2020 and recorded across a variety of acoustic microbarometer sensors. This report details the waveform data recorded from the experiment and coincides with data archival at the Incorporated Research Institutions for Seismology. The report includes a description of the experiment along with the types of data and instruments. The data release includes raw waveform data as well as metadata information.

47 OTHER INSTRUMENTATION↗
DOE OSTI2024

Lab Collaboration Project (LCP) for Marine Energy: Quantifying Collision Risk for Fish and Turbines Final Technical Report (Task 10)

A persistent environmental concern for the widespread deployment of tidal turbines is the potential for fish and marine mammals to collide with rotating blades (Copping et al. 2016, Copping and Hemery 2020). This is a consequence of well-documented bird and bat mortalities around wind turbines (Smallwood 2007, Thompson et al. 2017), as well as fish mortality at conventional hydropower dams (Pracheil et al. 2016) and tidal barrages (Dadswell and Rulifson 1994). However, unlike hydropower dams or barrages, tidal turbines do not involve structures that channel all flow through the turbines. Similarly, while functionally similar to wind turbines, tidal turbines often operate at lower relative velocities and, depending on the end-use application, may be significantly smaller than utility-scale wind turbines. Both of these factors reduce the likelihood and severity of collision, but the knowledge base on this topic remains limited.

13 HYDRO ENERGY↗
DOE OSTI2022

Application of Multiharmonic QCM-D for Detection of Plasmin at Hydrophobic Surfaces Modified by β-Casein

Plasmin protease plays an important role in many processes in living systems, including milk. Monitoring plasmin activity is important for control of the nutritional quality of milk and other dairy products. We designed a biosensor to detect the proteolytic activity of plasmin, using multiharmonic quartz crystal microbalance with dissipation (QCM-D). The β-casein immobilized on the hydrophobic surface of 1-dodecanethiol on the AT-cut quartz crystal was used to monitor plasmin activity. We demonstrated detection of plasmin in a concentration range of 0.1–20 nM, with the limit of detection about 0.13 ± 0.01 nM. The analysis of viscoelastic properties of the β-casein layer showed rapid changes of shear elasticity modulus, μ, and coefficient of viscosity, η, at plasmin sub-nanomolar concentrations, followed by modest changes at nanomolar concentrations, indicating multilayer architecture β-casein. A comparative analysis of viscoelastic properties of β-casein layers following plasmin and trypsin cleavage showed that the higher effect of trypsin was due to larger potential cleavage sites of β-casein.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Surface Acoustic Wave H2 and O2 Sensors Based on Conducting Metal Oxides/Langasite for Elevated Temperature Applications - presentation

<p style="text-align: justify;"><span style="font-family: Arial; font-size: 10pt;">• </span><span style="color: black; font-family: Arial; font-size: 10pt;">SAW reflective delay line devices were designed and successfully fabricated on Langasite by patterning platinum electrodes.</span><p style="text-align: justify;"><span style="font-family: Arial; font-size: 10pt;">• </span><span style="color: black; font-family: Arial; font-size: 10pt;">Fabricated devices successfully tested up to 500°C for temperature sensing applications.</span><p style="text-align: justify;"><span style="font-family: Arial; font-size: 10pt;">• </span><span style="color: black; font-family: Arial; font-size: 10pt;">Indium oxide (IO) and indium tin oxide (ITO) sensing layers were developed on the SAW devices using sputtering and sol-gel method.</span><p style="text-align: justify;"><span style="font-family: Arial; font-size: 10pt;">• </span><span style="color: black; font-family: Arial; font-size: 10pt;">IO- and ITO-functionalized langasite SAW reflective delay line devices were used for sensing H2 and O2 at 350°C. </span><br>

Mao, Elizabeth↗
DOE OSTI2020

Thermally-Induced Breakouts: Insights from True-Triaxial Tests with Acoustic Emission Monitoring

Borehole breakouts are used to constrain the magnitude of maximum horizontal stress. However, when the borehole wall strength is higher than the in situ tangential stress, borehole wall failure does not develop. Additional compressive stress can be induced by heating borehole walls. To validate this concept experimentally, we conducted room-temperature and elevated temperature true-triaxial tests on Berea sandstone and Niagaran dolomite samples. We used acoustic emission sensors to capture the onset of breakout development, and we measured the temperature close to borehole wall to assess the magnitude of induced thermal hoop stress. The test results show that within a specific rock type, the breakouts develop in similar manner in room-temperature and elevated-temperature tests. Therefore, the maximum horizontal stress can be constrained from the following dataset: critical tangential stress at which breakout develops, minimum horizontal stress, elastic and thermal properties, and temperature change at the borehole wall.

Trzeciak, Maciej↗