Learning a Reliable Compression of In-situ, High-speed Camera Data for Additive Manufacturing
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Yen, Tian Yu↗
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Low latency optical-based mode tracking with machine learning deployed on FPGAs on a tokamak
Active feedback control in magnetic confinement fusion devices is desirable to mitigate plasma instabilities and enable robust operation. Optical high-speed cameras provide a powerful, non-invasive diagnostic and can be suitable for these applications. Here, in this study, we process high-speed camera data, at rates exceeding 100 kfps, on in situ field-programmable gate array (FPGA) hardware to track magnetohydrodynamic (MHD) mode evolution and generate control signals in real time. Our system utilizes a convolutional neural network (CNN) model, which predicts the n = 1 MHD mode amplitude and phase using camera images with better accuracy than other tested non-deep-learning-based methods. By implementing this model directly within the standard FPGA readout hardware of the high-speed camera diagnostic, our mode tracking system achieves a total trigger-to-output latency of 17.6 μs and a throughput of up to 120 kfps. This study at the High Beta Tokamak-Extended Pulse (HBT-EP) experiment demonstrates an FPGA-based high-speed camera data acquisition and processing system, enabling application in real-time machine-learning-based tokamak diagnostic and control as well as potential applications in other scientific domains.
46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
L-PBF High-Throughput Data Pipeline Approach for Multi-modal Integration
Abstract Metal-based additive manufacturing requires active monitoring solutions for assessing part quality. Multiple sensors and data streams, however, generate large heterogeneous data sets that are impractical for manual assessment and characterization. In this work, an automated pipeline is developed that enables feature extraction from high-speed camera video and multi-modal data analysis. The framework removes the need for manual assessment through the utilization of deep learning techniques and training models in a weakly supervised paradigm. We demonstrate this pipeline’s capability over 700,000 high-speed camera frames. The pipeline successfully extracts melt pool and spatter geometries and links them to corresponding pyrometry, radiography, and processparameter information. 715 individual prints are examined to reveal melt pool areas that exceeds 0.07 mm 2 and pyrometry signal over a threshold (375 pyrometry units) were more likely to have defects. These automated processes enable massive throughput of characterization techniques.
36 MATERIALS SCIENCE↗
Continuum laser absorption spectroscopy of C 2 (a 3 Π u ) in a sublimating cloud of carbon black
A direct optical absorption diagnostic has been developed for rotationally resolved measurements of diatomic carbon (a 3 Π u →d 3 Π g (0,0) and (1,1)) at a repetition rate of 525 kHz and resolution of 7.3 pm over the range of 511.1–514.1 nm. The diagnostic utilizes a high-power pulsed continuum laser light source dispersed in a spectrograph and imaged by a high-speed camera. Measurements have been performed that capture the temporal evolution of C 2 number density and temperature of a cloud of carbon black sublimating in shock heated gas at high temperature and pressure (T = 5500 K, P = 3.7 atm). A simultaneous light absorption measurement of the condensed phase enables comparisons of the gaseous C 2 number density to the condensed phase mass. The continuum laser absorption diagnostic is applied to C 2 in this work but shows promise in being a simple “drop-in” system for absorption spectroscopy in the visible range at rapid repetition rates and high dispersion, filling an important gap for laser diagnostic systems.
Willhardt, Colton Dean [Univ. of Illinois at Urban↗
Radioimaging for real-time tracking of high-voltage breakdown
Development of a radioimaging diagnostic for high-voltage component reliability testing and electrical breakdown computational model validation is described. Radioimaging has its roots in radio astronomy, where aperture synthesis (also known as synthesis imaging) has been utilized for decades to image radio sources far from Earth. Radioimaging as described herein, in contrast, seeks to image radio sources in close proximity to its receivers (i.e., in a laboratory environment). Here it is shown that corona discharge, a non-destructive precursor to catastrophic (thermal) arc discharge, electromagnetically radiates strongly within a 250 kHz – 2.5 GHz bandwidth, and is readily detected and located by postprocessing the received radio signals. The ability of radioimaging to detect both corona and arc discharge (grouped together herein as high voltage breakdown or HVB) makes it a valuable tool for 100% HVB detection in materials, components, and devices, and has the ability to indicate electrical weakness (via corona detection) prior to a destructive arc discharge event. Radioimaging enables HVB to be located both internal and external to dielectric components under test in near-real-time, with multiple and/or extended HVB events located simultaneously. In contrast, existing non-destructive diagnostics (at the time of this writing) either indicate electrical breakdown without resolving failure locations (e.g., current, voltage, and chemical measurements), locate external HVB (e.g., high-speed optical and ultraviolet (UV) measurements or photography), or locate both external and internal HVB but with low fidelity (e.g., a single HVB source can be located by existing time-of-arrival (TOA) UHF or acoustic emissions). Radioimaging instead creates a sequence of high-fidelity images similar to an optical high-speed camera but at radiofrequencies (RF), and is not limited to two-dimensions. Moreover, radioimaging has already served one internal and two external industry customers, the results of which are detailed in this report. The radioimaging results described herein were part of a three-year effort funded by the Sandia Lab Directed Research and Development (LDRD) program within the Radiation, Electromagnetic, High Energy Density Science (REHEDS) investment area.
47 OTHER INSTRUMENTATION↗
Deep learning-based spatio-temporal fusion for high-fidelity ultra-high-speed X-ray radiography
Full-field ultra-high-speed (UHS) X-ray imaging experiments have been well established to characterize various processes and phenomena. However, the potential of UHS experiments through the joint acquisition of X-ray videos with distinct configurations has not been fully exploited. In this paper, we investigate the use of a deep learning-based spatio-temporal fusion (STF) framework to fuse two complementary sequences of X-ray images and reconstruct the target image sequence with high spatial resolution, high frame rate and high fidelity. We applied a transfer learning strategy to train the model and compared the peak signal-to-noise ratio (PSNR), average absolute difference (AAD) and structural similarity (SSIM) of the proposed framework on two independent X-ray data sets with those obtained from a baseline deep learning model, a Bayesian fusion framework and the bicubic interpolation method. The proposed framework outperformed the other methods with various configurations of the input frame separations and image noise levels. With three subsequent images from the low-resolution (LR) sequence of a four times lower spatial resolution and another two images from the high-resolution (HR) sequence of a 20 times lower frame rate, the proposed approach achieved average PSNRs of 37.57 dB and 35.15 dB, respectively. When coupled with the appropriate combination of high-speed cameras, the proposed approach will enhance the performance and therefore the scientific value of UHS X-ray imaging experiments.
deep learning↗
Fractal Scaling of Explosively Driven Product Gases
ABSTRACT Characterization of the interface between explosive product gases and ambient air in an explosion is a complicated task due to the turbulent mixing and inherently three‐dimensional expansion of the interface. This study aims to quantify the evolution of the interface as a temporally varying Hausdorff dimension. Two test series were conducted with Composition C‐4 charges with masses of 105 and 880 g. Imaging data were collected from the time of detonation until shock wave detachment using ultra‐high‐speed cameras. Gas cloud profiles were extracted using automated image processing algorithms, and the Hausdorff dimension of these two‐dimensional slices of the gas cloud was then estimated using boxcounting algorithms. When scaled with standard gas dynamic nondimensional scalings, the Hausdorff dimension of all explosive events appears to collapse towards a single curve. The fireball was initially nonfractal and began to develop fractal properties as the shock wave separated from the detonation products. Artificial perturbation of the charged surface had no detectable impact on the evolution of the Hausdorff dimension in the early development of the fireball outside of error, despite visible phenomenological differences in the early development of mixing on the fireball surface.
42 ENGINEERING↗
Characterization of the fractal dimension of helium plumes in laminar to turbulent transition
Abstract Schlieren imaging in conjunction with a high-speed camera was used to observe the behavior of metered helium plumes as they transition from laminar to turbulent flow in an air environment. The plumes were visualized at twelve jet Reynolds numbers ranging from 200 to 2980. The fractal dimension of the flows was obtained by applying a box counting algorithm to the recorded schlieren images. The results were analyzed to determine the correlation between the Reynolds number of the flow and the fractal dimension of the observed turbulence. A trend of increasing fractal dimension with increasing Reynolds number was observed for several different types of schlieren cutoffs including horizontal cutoff, vertical cutoff, circular cutoff, focused shadowgraphy and de-focused shadowgraphy. The vertical cutoff and focused shadowgraphy imaging methods showed the most consistent results for the fractal dimension characterization during the laminar to turbulent transition. For transitional plumes, it was observed that fractal dimension increased with distance from the jet outlet.
42 ENGINEERING↗
Quantifying particle movement in a spout-fluidized bed with irregular feedstock morphology
Here, the spout-bed fluidization behavior of nonspherical, 140 μm SiC feedstock was quantified via particle image velocimetry for varying gas distributor geometries. A bench-scale, room-temperature fluidization setup was assembled to model a 50 mm fluidized bed chemical vapor deposition (FB-CVD) system, and fluidized bed motion was captured using a high-speed camera. Modular tips with varying inlet geometries were 3D printed and tested on the bench-scale rig using identical feedstock and gas flow rates in the range of 3.0–9.0 L/min. Fluidization behavior was quantified by extracting parameters of the bed velocity, frequency, dead time, and other measurements, which were ranked for each inlet geometry configuration tested. The results from this work demonstrate that changing the path of inlet gas flow can significantly change the hydrodynamics within a spout-fluidized bed under identical feedstock, loading, and flow rate conditions, potentially enabling experimental control of particle fluidization behavior for a given condition. Moreover, composite rankings of fluidization behavior for unique distributor geometries hold potential to guide the design of FB-CVD experiments for various engineering and scientific applications.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Effect of a collapsing gas bubble on the shock-to-detonation transition in liquid nitromethane
We studied the shock-induced collapse of butane gas bubbles in the homogeneous explosive nitromethane (NM) to investigate the effects of hot spot formation on the detonation process. A butane bubble was injected into a sample of NM, and a shock wave from a flat plate impactor compressed the bubble, creating a localized hot spot. We measured shock and detonation wave speeds with optical velocimetry, and we used a high-speed camera to image the shock propagation and bubble collapse processes. A multiband optical fiber pyrometer measured the time-resolved thermal radiance, and we used the results and emissivity values extracted from spectral fits to estimate temperatures. We measured the characteristics of the shock-to-detonation transition in NM with and without a bubble. All experiments were performed at shock pressures near 8 GPa, where neat NM can detonate. A single bubble in this system was shown to sensitize NM, leading to a reduced run-to-detonation time. We used hydrodynamic modeling to predict shock wave propagation, the extent of chemical reaction, and subsequent temperature rise from the collapsing bubble. We used a temperature-dependent Arrhenius burn model for simulations, and it yielded much better results than reactive burn models that depend only on pressure and density.
46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
Plasma modification through boron particulate injection in the full tungsten environment of WEST
Recent experiments have confirmed the compatibility of extended boron particulate injections with high performance plasma discharges in the full tungsten (W) environment of WEST. Utilizing an impurity powder dropper (IPD) equipped with boron (B) powders a series of extended experimental programs providing controlled injections have quantified plasma response to varying levels of injection rate and total injection quantity. Calibration of injection quantities confirmed through post-situ testing of the IPD and cross-correlated with both high-speed camera illumination and spectroscopic measurement have allowed for the first time a fine scale determination of the effects of powder introduction on plasma performance. Plasma enhancement, consistent with turbulence reduction through profile modification, has been observed with sustained increases in the stored energy (WMHD), by 18%, electron temperature (T e ) by 35%, and neutron rate (N n ) by up to 200%, all of which scale positively with increasing powder injection rates. These injections have also resulted in both prompt and extended reductions in native impurity content, decreases in post injection radiated power, and strong decreases in divertor deuterium signatures signifying a reduction in recycling suggesting enhanced boron layer formation which provides a reduction of source terms and leads to enhanced gettering of main ion and impurity sources.
Lunsford, R. [Princeton Plasma Physics Laboratory ↗
Background-Oriented Schlieren Velocimetry of Helium Coolant Flow in Additively Manufactured Channels
High-pressure helium gas cooling is an attractive solution for thermal management of the fusion blanket first wall, as this coolant is chemically and neutronically inert and separable from hydrogenic species. However, due to the low thermal mass of helium, geometric optimization of these channels is required to provide sufficient cooling at manageable flow rates and pumping burdens. Increasingly, analysis and optimization of these coolant channels rely on computational fluid dynamics (CFD) simulations, and these require relevant experimental data for turbulence model validation. Toward this end, a high-pressure helium gas flow visualization system has been employed to image the flow of helium in flow channels with one-sided heating, mimicking the blanket first wall environment. Flow of helium at 4 MPa pressure and flow rates up to 68 g/s (Reynolds number 57 000) is supplied to rectangular channel test sections, with uniform heating applied to the bottom wall of the channel at heat fluxes varied between roughly 50 and 130 kW/m2. A high-speed camera is used to image index of refraction (IOR) gradients in the fluid via background-oriented schlieren (BOS), and temperature and pressure instrumentation are used to characterize thermal-hydraulic performance of each channel. Cross correlation of time-resolved BOS images is then used to calculate time-averaged 2-D helium velocity fields. Flow in additively manufactured (AM) channels is examined in this manner, including both featureless channels and those containing baffling as a heat transfer enhancement. The flow distribution seen in the featureless case differs significantly from that seen in prior simulations, whereas the flow in the baffled case shows the predicted behavior of flow forced along the heated wall. This augmented flow distribution is seen to increase the heat transfer coefficient in the baffled test section. Here, strategies are discussed for ongoing and future validation of these simulations, with the aim of model deployment for blanket cooling design and optimization.
Additive manufacturing↗
Optical Flow Diagnostics of Counter Fluidization of Gravity-Driven Moving Packed Bed for a CSP Receiver Section Featuring Staggered Array of Cylindrical Pins
Particle fluidized beds have the potential to improve the efficiency of heat transfer in concentrated solar receiver furnace for use in next generation concentrated solar power (CSP) plants. This study presents an experimental investigation on the flow characterization of vertically downward moving packed bed with counter fluidization through an array of jets. To control the bubble size and its distribution in the bubbling fluidized bed, an array of cylindrical pin fins was arranged uniformly across the test article. The flow visualization was performed on the surface of transparent glass coated with electrically conductive materials for electrostatic dissipation purposes. The image acquisition was carried out via high-speed camera at a frequency of ~ 1kHz. The acquired images were analyzed in pairs with the help of a modern optical flow algorithm capable of calculating the movement of dense particle flow in the fluidized bed by tracking the light intensity of each predefined window of the frames. A comparison of fluidized beds with plane and pin-finned channels revealed distinct bubble behavior. Pin-finned channels were found to produce a larger number of small-sized bubbles, while plane channels generated fewer but larger bubbles at any given instant. The presence of pin fins was observed to reduce bubble size by preventing bubble merging and splitting larger bubbles when they encountered a pin.
concentrating solar power↗
Heat transfer and visual observation of pool boiling of next-generation low-pressure refrigerant: R1336mzz(Z)
R1336mzz(Z) is a non-flammable and non-toxic hydrofluoroolefin (HFO), which is a potential alternative working fluid for multiple applications such as centrifugal chillers, industrial high temperature heat pumps, and Organic Rankine Cycles. Pool boiling is one of the primary heat transfer modes in shell-and-tube evaporators, and there is limited data for R1336mzz(Z) due to its recent introduction. This study investigated the pool boiling characteristics of R1336mzz(Z) using a closed-loop apparatus. Heat transfer coefficients on a smooth aluminum surface were measured at various heat fluxes with a heating block, and the results were compared to predictions from various correlations. Additionally, a high-speed camera was employed to visualize and analyze the pool boiling behavior of this next-generation low-pressure refrigerant.
Yang, Cheng-Min [ORNL]↗
Microchannel Geometries for Improved Heat Transfer with Low-GWP refrigerants
Due to efforts aimed at decarbonizing industries, the use of refrigerants with low global warming potential (GWP) is highly recommended in the air-conditioning and refrigeration sectors. Despite possessing low-GWP values of less than 150, hydrofluoroolefins (HFO) exhibit relatively lower heat transfer performance compared to conventional hydrofluorocarbons (HFC) under certain operating conditions. In contrast to HFCs, there is a high demand for enhanced surfaces to meet the needs of heat transfer systems utilizing low GWP refrigerants. Accordingly, this study analyzes the pool boiling performance of low-GWP refrigerants in microchannel geometries. The experiments were carried out at various heat flux levels on both smooth and enhanced surfaces. The pool boiling behavior of low-GWP refrigerant R1234yf was compared to that of R-134a refrigerant in terms of heat transfer coefficient and wall superheat. The results indicate that the heat transfer coefficients of the enhanced surface are significantly higher than those of the smooth surface. Furthermore, the microchannel geometry demonstrated a lower wall superheat compared to the smooth surface. Additionally, a visualization study was performed using a high-speed camera to understand the pool boiling mechanism of low-GWP refrigerants on both smooth and enhanced surfaces.
Murugan, Muneeshwaran↗
Multi-frequency signatures of space-leader evolution in negative cloud-to-ground lightning stepped leaders
In this study, we examined 364 space leaders in 18 negative natural cloud-to-ground lightning strokes whose stepped leaders created new channels to ground. All strokes were captured on ultra-high-speed video cameras operating at frame rates ranging from 400k to 783k frames per second. Additionally, broadband electromagnetic field measurements were available for a subset of these strokes. The median space leader inception-to-attachment-point length and retrograde propagation speed towards the pre-existing leader channel (PELC) were 8.2 m and 4.0 x 10 6 m/s, respectively. Space leader lengths were longer and retrograde propagation speeds faster for return strokes with higher peak currents. This is likely due to the relative proximity of space leader inception points to the PELC, which makes the electric field produced by the PELC line charge density one of the primary factors in determining space leader characteristics. Space leader characteristics were weakly related to their inception altitude. We observed bursts of very high frequency (VHF) emissions preceding, by around 0.5 – 1 μs, electric field leader-step pulses; visible-frequency-range luminosity pulses started during the step pulses. The median downward leader propagation speed for all 18 strokes was 4.3 x 10 5 m/s; leader propagation speeds were generally faster for return strokes with higher peak currents. Also, leaders appeared to accelerate (on their way to ground) at altitudes lower than about 200 and 1000 m above ground level for strokes in the 10 – 60 and 84 – 228 kA peak current ranges, respectively.
54 ENVIRONMENTAL SCIENCES↗
High-speed particle analysis using forward and backward two-dimensional angular optical scattering
Measurement of two-dimensional angle-resolved optical scattering (TAOS) patterns is an attractive technique for detecting and characterizing micron-sized high-speed flying particles. The elastic-scattering intensity pattern from a single particle as a function of spherical coordinate angles θ and ϕ provides detailed information on the particle’s morphology. By use of an ellipsoidal reflector and a high-speed CCD camera, scattering from a CW-laser was detected and resolved over a large angular range (θ from 12° to 168° and ϕ from 0° to 360°) from spherically shaped particles (e.g., amorphous silica and borosilicate glass) flowing through the reflector’s focal plane at speeds of 20 to 30 m/s. The scattering pattern from individual particles flying through the focal plane of the ellipsoid mirror provides insights about a particle’s size, clustering, roughness, and velocity.
Optics and optical instruments↗
Department of Transportation PHMSA Aerosol Spray Project: Phase-0
This report discusses the work conducted at Sandia National Laboratories during the preliminary phase (Phase-0) of the Department of Transportation (DOT) Pipeline and Hazardous Materials Safety Administration (PHMSA) project tasked to better understand what happens to a high-pressure liquid canister or vessel during a fire in which an accidental instantaneous release occurs. Phase 0 had two main objects: (1) to establish a methodology for the high temperature and pressure spray vessel release and (2) to characterize the spray droplet formation. For this test series, diagnostic equipment such as the Malvern Spraytec, high-speed photometric cameras, pencil gauges, and thermocouples were used. Additionally, the effect of surface tension on the particle size distribution was evaluated with 1-liter of distilled water and with the same including the addition of 0.5% soap/water mixture. Results from this effort indicated that the plume formed from the instantaneous release in all conditions primarily included two distinct particle size distributions including 217-312µm and 0.53µm on average. Soapy water formed a higher concentration of smaller mist (0.53µm) than distilled water, potentially due to decreased surface tension with the added surfactant. Though results showed good correlation to certain particle size distributions it is encouraged to conduct additional tests like this with a wider range of liquids with different properties, which could affect the overall particle size distribution when released.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗