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At least 145 records · Page 8

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NASA NTRS2007

Post-Flight Analysis of Selected Fluorocarbon and Other Thin Film Polymer Specimens Flown on MISSE-5

Twenty thin film specimens were flown on M1SSE-5 as a cooperative effort between several organizations. This presentation will report results of initial inspections and post-flight measurements of the optical properties and recession of these materials due to the approx.13 month exposure period on the exterior of the International Space Station. These specimens were located on the "anti-solar" side of the MISSE-5 container and received a low number of Equivalent Sun Hours of solar UV exposure. Profilometry and/or ATF measurements will be conducted to determine thickness changes and atomic oxygen-induced recession rates Six of the specimens were covered with thin Kapton films, 0.1 and 0.3 mil in thickness. The 0.1 mil Kapton was almost completely eroded, suggesting that the atomic oxygen fluence is <8 x 10(exp 19) atoms/sq cm, similar to levels experienced during Space Shuttle materials experiments in the 1980's and 1990's. A comparison of results from MISSE-5 and Space Shuttle experiments will be included for those materials common to both the short and long-term exposures.

DeGroh, Kim↗

DOE OSTI2021

The effect of longer-range waviness on X-ray reflectivity measurements

A model for calculating the X-ray reflectivity (XRR) of surfaces to extract both roughness and waviness features is presented. Expressions of reflectivity intensity are derived as a function of root-mean-square (RMS) roughness σ, RMS waviness σ L , and the cut-off frequency between the features ω 0 . Experiments were conducted at the Advanced Light Source at Lawrence Berkeley National Laboratory, beamline 8.3.2, on BK7 glass manufactured with a multi-step polishing process to validate the model, and were compared with atomic force microscopy (AFM), Fizeau interferometry and surface profilometry measurements. Here, the parameter results and their deviations for XRR measurements were σ = 2.9 ± 0.2 nm and σ L = 14.6 ± 0.5 nm with a wavelength cut-off of 1/(18 ± 2) µm –1 , while the results from the AFM, Fizeau and profilometry measurements were σ AFM = 3.4 ± 0.4 nm, σ L,Fizeau = 21.6 nm, σ prof = 4.0 ± 0.1 nm, and σ L,prof = 21.4 ± 0.1 nm with cut-offs for the profilometry and Fizeau measurements limited to frequencies of (1/16) µm –1 to (1/4) mm –1 .

42 ENGINEERING↗

DOE OSTI2025

Assessing High Burnup U-19Pu-10Zr Fuel Performance against Historical and Modeled Behavior

Advancing the deployment of sodium-cooled fast reactors (SFRs) requires thorough testing of metallic fuel pins under accident conditions to establish safe operational limits of high burnup fuel. To conduct transient testing, a comprehensive understanding of steady-state fuel behavior obtained through both experimental characterization and accurate predictive capabilities is needed. This study comparatively assesses the steady-state irradiation performance of two high burnup U-19Pu-10Zr fuel pins, DP-36 and DP-40, irradiated under prototypic fast reactor conditions in preparation for planned safety testing at the Transient Reactor Test Facility. Since DP-40 was designated for use in the test and DP-36 serves as its sibling pin, non-destructive, engineering-scale post-irradiation examinations (PIE) were conducted on both pins while destructive examinations were performed exclusively on DP-36. The results were then assessed against historical performance data from similar fuel pins irradiated in the Experimental Breeder Reactor-II. Additionally, the steady-state irradiation of each pin was modeled using the BISON fuel performance code to assess the accuracy of current modeling capabilities in predicting the baseline irradiation behavior. Non-destructive examinations included neutron radiography to measure fuel column elongation, gamma scanning to verify pin integrity and fission product migration, and profilometry to assess dimensional changes. Benchmarking against existing PIE data revealed consistent patterns in axial fuel column growth and cladding diametral strain, though both pins exhibited longer low-density “fluff” structures, which can have implications for core reactivity and source term calculations. Destructive examinations on DP-36 included fission gas release analysis and sectioning for optical microscopy, which showed more complex constituent redistribution patterns than the traditionally accepted 3-ring model. The axial evolution of fractional areas and porosities of each of the redistributed zones were quantified and presented. Modeling comparisons showed agreement in fractional fission gas release but consistently overestimated axial and radial swelling and disagreed with measured axial porosity patterns. These conservative overpredictions suggested that the pins would appear closer to failure or operational limits at the start of transient tests, potentially leading to higher strain accumulation during the transient. While conservative estimates provide safety margins, they can negatively impact fuel economics. A review of the swelling models identified areas for improvement in the gaseous swelling, solid swelling, and fuel hot-pressing models when applied to ternary fuel. The results of this study highlight the critical importance of conducting pre-test characterization on both test and sibling pins to accurately capture steady-state fuel behavior, providing a precise baseline for post-test evaluations and essential inputs for transient modeling of the planned experiments. The analysis also revealed significant data gaps that require further investigation to enhance the understanding and prediction of fuel swelling and pore dynamics. Collecting comprehensive data across different irradiation conditions, burnup levels, and fuel compositions are essential for refining existing models and developing mechanistic models for both binary and ternary metallic fuels, ultimately improving the integration of modeling and experimental approaches in accident testing.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS1990

Robust, angstrom level circularity profilometry

A noncontacting approach is presented which involves measuring the local circumferential curvature of the test piece by simultaneously measuring its circumferential slope at two slightly displaced locations. A pair of sensing beams is scanned along the circumference, and a profile of curvature is built, from which the circularity profile is deduced. The sensing of curvature makes the approach insensitive to all types of vibration and drift and runout errors in the relative rotation. The special qualities of the approach are summarized which make it well suited to measuring cylindrical optics and enable it to accommodate radii as small as twenty millimeters.

Glenn, Paul↗

DOE OSTI2019

Structural, optical and electrical behavior of zinc oxide/MWCNT composite thin films

ZnO/MWCNT composite thin films were prepared on glass substrates by spray pyrolysis, and their structural and optical behavior were investigated. X-ray diffraction analysis revealed the films hexagonal wurtzite phase with a preferred (002) growth orientation. Photoluminescence spectra of the ZnO film showed two main bands, a UV emission band at 377 nm (3.28 eV) and a broad blue-yellow band at 439–546 nm with a band at 503 nm. Optical transmittance of 80–85% in the visible range was observed in all the films. In the I–V curves, conductivity was improved when incorporating the MWCNT into the zinc oxide. ZnO/MWCNT, at a value of 2 V and irradiated with visible light presented an increased current from 0.6 to 3.2 nA, and a similar pattern was observed when impinging UV light. Film thickness was measured by profilometry, obtaining thicknesses in the range from 143 to 257 nm.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

NASA NTRS1990

Robust, sub-angstrom level mid-spatial frequency profilometry

A noncontacting measurement approach is presented that involves the measurement of the local curvature of the test piece by simultaneously measuring its slope at two slightly displaced locations. As the sensing beams are scanned along the test piece, a profile of curvature is built, from which the height profile is deduced by double integration. The sensing of curvature eliminates the need for a reference surface, and makes the approach insensitive to all types of vibration and drift, both in surface height and in surface slope. The approach is considered to be well suited to measuring grazing incidence optics with highly different transverse and longitudinal radii of curvature. Implementation features including a steering mirror and a movable detector provide for servo tracking of test pieces as fast as F-0.5, with radii as small as 20 mm (convex or concave).

Glenn, Paul↗

NASA NTRS2018

In-situ Diagnostic for Assessing Hall Thruster Wear

The design of a new diagnostic to measure the net erosion of Hall thruster surfaces is presented. This diagnostic consists of a pair of optical noncontact profilometer pens mounted to a set of motion stages, which can interrogate the surface features of multiple components of interest including the hollow cathode assembly, magnet front pole covers, and discharge channel. By comparing scans of these surfaces to reference features, estimates of the component erosion rates can be acquired throughout long-duration lifetime tests without venting and removing the thruster from the vacuum facility for external profilometry. This work presents a detailed overview of the diagnostic design including the precision positioning system. In addition, preliminary data are shown which verify diagnostic operation and establish a baseline that will be used to track the erosion of the Hall Effect Rocket with Magnetic Shielding (HERMeS) Technology Demonstration Unit 3 (TDU-3) during an ongoing long-duration wear test.

Ahern, Drew M.↗

DOE OSTI2019

Optimization of the size and shape of the scanning aperture in autocollimator-based deflectometric profilometers

Deflectometric profilometers based on industrial electronic autocollimators (ACs), as the ELCOMAT-3000, have become indispensable tools for precision form measurements of optical surfaces. A growing number of labs at synchrotron and free electron laser x-ray facilities are going for BESSY-II NOM-like versions of the AC-based profilometers. These tools have proven capable of characterizing state-of-the-art aspherical x-ray optics with an accuracy on the level of 100 nrad (root-mean-square) over the spatial frequency range limited by the size of the aperture used in the profilometer. Normally, a round aperture with a diameter of about 2.5 mm is used. Previous investigations have shown that with the optimally aligned 2.5-mm aperture, the spatial resolution of a NOM-like profilometer corresponding to the first zero-crossing of the optical transform function (OTF) is ~1.2 mm. In this paper, we investigate the performance of an AC ELCOMAT-3000 for a slope profilometer with different aperture sizes and shapes. The results of angular calibration of the AC equipped with circular and rectangular apertures placed at different distances from the AC are discussed. The calibration was performed at the Physikalisch-Technische Bundesanstalt using the original experimental arrangements, also discussed in the paper. The OTF measurements with the specially developed test sample with chirped surface slope profiles were performed at the Advanced Light Source X-Ray Optics Laboratory (XROL) in application to a new optical surface measuring system under development at the XROL. In the OTF measurements, we have shown that application of a rectangular aperture with dimensions of 1.5 mm × 3 mm improves the spatial resolution in the tangential direction by a factor of ~1.4 compared to that of the standard circular aperture of 2.5-mm diameter. We postulate that the conclusions of our investigations are crucial for reaching fundamental metrological limits in deflectometric profilometry utilizing state-of-the-art electronic autocollimators.

47 OTHER INSTRUMENTATION↗

NASA NTRS1983

Precision machining technology and metrology for AXAF study

The optical surfaces for the Advanced X-ray Astrophysical Facility (AXAF), was studied. The applicability of precision machining technology to the manufacture of the AXAF objective mirrors and the proposed and alternative methods for manufacturing and testing; (1) the AXAF technology mirrors and (2) the AXAF high resolution mirror assembly were reviewed. Surface shape and smoothness metrology for grazing incidence X-ray surfaces and the feasibility of applying heterodyne surface profilometry to nonflat surfaces were investigated. Three sets of scattering flats with known surface profiles and microtopographic character produced by precision machining and polished precision machine surfaces were analyzed.

Sanger, G. M.↗

NASA NTRS2018

In-Situ Diagnostic for Assessing Hall Thruster Wear

The design of a new diagnostic to measure the net erosion of Hall thruster surfaces is presented. This diagnostic consists of a pair of optical non-contact profilometer pens mounted to a set of motion stages, which can interrogate the surface features of multiple components of interest including the hollow cathode assembly, magnet front pole covers, and discharge channel. By comparing scans of these surfaces to reference features, estimates of the component erosion rates can be acquired throughout long-duration lifetime tests without venting and removing the thruster from the vacuum facility for external profilometry. This work presents a detailed overview of the diagnostic design including the precision positioning system. In addition, preliminary data are shown which verify diagnostic operation and establish a baseline that will be used to track the erosion of the Hall Effect Rocket with Magnetic Shielding (HERMeS) Technology Demonstration Unit 3 (TDU-3) during an ongoing long-duration wear test.

Ahern, Drew M.↗

NASA NTRS2018

In-Situ Diagnostic for Assessing Hall Thruster Wear

Ahern, Drew M.↗

NASA NTRS1991

Laser interferometric measurement of ion electrode shape and charge exchange erosion

A novel projected fringe profilometry system was applied to surface contour measurements of an accelerator electrode from an ion thruster. The system permitted noncontact, nondestructive evaluation of the fine and gross structure of the electrode. A 3D surface map of a dished electrode was generated without altering the electrode surface. The same system was used to examine charge exchange erosion pits near the periphery of the electrode to determine the depth, location, and volume of material lost. This electro-optical measurement system allowed rapid nondestructive digital data acquisition coupled with automated computer data-processing. In addition, variable sensitivity allowed both coarse and fine measurements of objects having various surface finishes.

Macrae, Gregory S.↗

DOE OSTI2017

Optical-based spectroscopic methods for measuring chemical, optical, and physical properties of thin polymer waveguide films

Non-destructive optical-based spectroscopic methods are needed for analyzing “real world” devices that consist of thin polymer waveguide films. Many applications (e.g., sensors, microelectronics, optics, and biomedical applications, etc.) utilize thin polymer waveguide films, and non-destructive characterization methods based on Fourier transform (FT)-plasmon waveguide spectroscopy (PWR) and scanning angle (SA) Raman spectroscopy are used to extract optical, physical, and chemical properties simultaneously. The FT-PWR method measures reflected light at polymer waveguide interface as both the incident frequency (wavelength) and incident angle are scanned. This method uses p- and s-polarized light to simultaneously extract the polymer waveguide thickness and apparent anisotropic indices of refraction. Polystyrene waveguide films ranging from 360 to 800 nm are used to demonstrate the method and it has an average 0.4% relative error when compared to profilometry and atomic force microscopy measurements. SA Raman spectroscopy is used to measure mixed waveguide polymer films consisting of polystyrene-block-poly(methyl methacrylate) and homopolymer poly(methyl methacrylate) (PS-b-PMMA:PMMA), and poly(2-vinylnapthalene)-block-poly(methyl methacrylate) (P2VN-b-PMMA). PMMA homopolymer is added to the PS-b-PMMA solutions to vary the chemical composition. The chemical composition of each mixed film is quantified (SA Raman peak amplitude ratios) and averaged over all incident angles and is termed the Raman amplitude ratio (rps). This parameter is used to calculate the refractive index of each mixed waveguide polymer film. The refractive index is an input parameter for sum square electric field (SSEF) calculations, which are used to model SA Raman spectra as a function of incident angle to extract the film thickness. The mixed polymer waveguide film thicknesses ranged from 495 to 971 nm, and the SA Raman spectroscopy method has an average 5% difference between the values determined by profilometry. The SA Raman spectroscopy method developed for mixed polymer waveguide films is used to measure the chemical composition and extract interface locations in bilayer and trilayer films consisting of PMMA/PS or PMMA/PS/PMMA, respectively. The rps value is averaged over angle ranges corresponding to waveguide mode 0 and waveguide mode 1 for the bilayer and trilayer films, respectively. Six multilayer films are analyzed and their total thicknesses range from 330 to 1260 nm. Iterative SSEF calculations are used to model the SA Raman spectra as a function of incident angle, and the best fit to the experimental data is used to extract the total thickness and interface location(s). The method has an axial spatial resolution of 7 to 80 nm and provides comparable values to films measured by profilometry with an average 8% and 7% difference for the bilayer and trilayer films, respectively.

36 MATERIALS SCIENCE↗

NASA NTRS1991

Laser interferometric measurement of ion electrode shape and charge exchange erosion

A projected fringe profilometry system was applied to surface contour measurements of an accelerator electrode from an ion thrustor. The system permitted noncontact, nondestructive evaluation of the fine and gross structure of the electrode. A 3-D surface map of a dished electrode was generated without altering the electrode surface. The same system was used to examine charge exchange erosion pits near the periphery of the electrode to determine the depth, location, and volume of material lost. This electro-optical measurement system allowed rapid, nondestructive, digital data acquisition coupled with automated computer data processing. In addition, variable sensitivity allowed both coarse and fine measurements of objects having various surface finishes.

Macrae, Gregory S.↗

DOE OSTI2016

Heterodyne frequency-domain multispectral diffuse optical tomography of breast cancer in the parallel-plane transmission geometry

Purpose: The authors introduce a state-of-the-art all-optical clinical diffuse optical tomography (DOT) imaging instrument which collects spatially dense, multispectral, frequency-domain breast data in the parallel-plate geometry. Methods: The instrument utilizes a CCD-based heterodyne detection scheme that permits massively parallel detection of diffuse photon density wave amplitude and phase for a large number of source–detector pairs (10{sup 6}). The stand-alone clinical DOT instrument thus offers high spatial resolution with reduced crosstalk between absorption and scattering. Other novel features include a fringe profilometry system for breast boundary segmentation, real-time data normalization, and a patient bed design which permits both axial and sagittal breast measurements. Results: The authors validated the instrument using tissue simulating phantoms with two different chromophore-containing targets and one scattering target. The authors also demonstrated the instrument in a case study breast cancer patient; the reconstructed 3D image of endogenous chromophores and scattering gave tumor localization in agreement with MRI. Conclusions: Imaging with a novel parallel-plate DOT breast imager that employs highly parallel, high-resolution CCD detection in the frequency-domain was demonstrated.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2026

Long-Length SiC/SiC Tube Irradiation Experiment at LWR Temperatures Inserted into HFIR

This report describes the pre-irradiation characterization and successful assembly of a High Flux Isotope Reactor (HFIR) irradiation experiment designed to assess radiation-induced lateral bowing of silicon carbide fiber–reinforced, silicon carbide matrix composite (SiC/SiC) components under a radial fast neutron flux gradient at representative light-water reactor (LWR) temperatures of approximately 300 °C. The over-arching goal of this work is to validate thermomechanical models of SiC/SiC composite fuel assembly distortion used to predict the extent of lateral bowing and dose at which bowing reaches a maximum value. Ultimately, these models are used to ensure that fuel assembly distortion does not block coolant channels, interfere with control rod/blade movements, and/or impact local reactivity. The experiment contains six cladding tube specimens that are approximately 558.5 mm long with representative pressurized water reactor (PWR) outer and inner diameters of 9.5 mm and 7.5 mm, respectively. The specimens were thoroughly characterized prior to irradiation using traditional dimensional inspection and surface profilometry so that these measurements can later be compared with similar measurements that will be made post-irradiation to determine radiation-induced deformations. Furthermore, fine engraving markers were inscribed along the outer surfaces of the specimen and mapped using analytic photography and a three-dimensional stage. This technique allowed for accurate measurements of the marker spacings, which can be compared with similar measurements that will be made post-irradiation to provide local radiation-induced strain mapping. A light curtain optical micrometer was also employed to measure the pre-irradiation bowing of each specimen. The experiment was successfully assembled and inserted into position VXF-19 for HFIR cycle 516, which began May 12, 2026. The experiment will be removed after cycle 519, which is currently scheduled to end in December 2026.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS1992

Mach 6 electroformed nickel nozzle refurbishment: FNAS investigation of ultra-smooth surfaces

The task objective has been to apply a coating of nickel-phosphorous alloy to a laminar flow wind tunnel nozzle by catalytic deposition and then polish and inspect the inside surface using optical device processes. The surface of the nozzle was coated with a nickel-phosphorous alloy of sufficient hardness and corrosion resistance to improve the durability. Due to plating defects that were clearly process related and not inherent, the final polished part was less than the desired quality. Surface finishing processes and lapping media were identified which produced a submicron surface finish on the interior plated surface. Defects apparently manifested by the first plating attempt were repaired using a small brush plating process demonstrating that individual small defects can be repaired. Measurement and analysis by profilometry demonstrated that quantitative control of the surface can be achieved.

Rood, Robert↗

DOE OSTI2024

3D Reconstruction of a High-Energy Diffraction Microscopy Sample Using Multi-modal Serial Sectioning with High-Precision EBSD and Surface Profilometry

High-energy diffraction microscopy (HEDM) combined with in situ mechanical testing is a powerful nondestructive technique for tracking the evolving microstructure within polycrystalline materials during deformation. This technique relies on a sophisticated analysis of X-ray diffraction patterns to produce a three-dimensional reconstruction of grains and other microstructural features within the interrogated volume. However, it is known that HEDM can fail to identify certain microstructural features, particularly smaller grains or twinned regions. Characterization of the identical sample volume using high-resolution surface-specific techniques, particularly electron backscatter diffraction (EBSD), can not only provide additional microstructure information about the interrogated volume but also highlight opportunities for improvement of the HEDM reconstruction algorithms. In this study, a sample fabricated from undeformed “low solvus, high refractory” nickel-based superalloy was scanned using HEDM. The volume interrogated by HEDM was then carefully characterized using a combination of surface-specific techniques, including epi-illumination optical microscopy, zero-tilt secondary and backscattered electron imaging, scanning white light interferometry, and high-precision EBSD. Custom data fusion protocols were developed to integrate and align the microstructure maps captured by these surface-specific techniques and HEDM. The raw and processed data from HEDM and serial sectioning have been made available via the Materials Data Facility (MDF) at https://doi.org/10.18126/4y0p-v604 for further investigation.

36 MATERIALS SCIENCE↗