Sources of error in vacuum calibration of heat flux sensors
Error sources in carbon black coating on thin foil heat flux sensors accounting for false altitude effects in vacuum calibration
Ash, R. L.↗
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A dynamic volumetric heat source model for laser additive manufacturing
Melt pool scale models of laser powder bed fusion (LPBF) offer insights into the process-structure-property relationships in additive manufacturing (AM). These models often neglect physical phenomena such as vapor cavity formation and fluid mechanics to reduce computational demands. Instead, volumetric heat source models are used to represent the effects that these phenomena have on the predicted melt pool dimensions. Generally, the dimensions and effective absorption of the volumetric heat source are calibrated to reproduce melt pool dimensions observed in metallographic cross sections taken from single-track experiments on bare plate. However, the transient nature of LPBF often deviates the melt pool dimensions from the assumed steady-state conditions of single-track experiments, motivating the need for a volumetric heat source model that more generally considers the dynamic relationship between melt pool shape and laser-material interactions. Here, we introduce a two-parameter volumetric heat source model that integrates several existing models into a generalized mathematical expression, providing independent control over the radial heat distribution via the parameter k and the volumetric shape of the heat source via the parameter m. This parameterization enables the calibration of melt pool shape predictions through simultaneous adjustment of these parameters, while keeping the radial heat source dimensions consistent with the experimental spot size (D4σ) and constraining the heat source depth and absorption to physically derived expressions for cavities. Consequently, the proposed volumetric heat source model adapts to changes in the local melt pool conditions due to scanning strategy and part geometry by dynamically adjusting the heat source depth and absorption. We demonstrate the capabilities of the proposed model through comparisons with a collection of experiments from the Additive Manufacturing Benchmark (AMBench).
36 MATERIALS SCIENCE↗
Computationally inexpensive part-scale thermal history of additive friction-stir deposition
This study presents an analytical model for steady-state power generation and tool heat loss in additive friction-stir deposition (AFSD), developed to enable part-scale thermal simulation while remaining computationally inexpensive. The model predicts total generated power, yielding 3.7–4.7 kW across deposition temperature setpoints of 400–460 °C for the deposition of AA6061 with a Be-Cu tool. This corresponds to 90–95% of the reported spindle power. Tool heat loss is experimentally determined by calibrating a steady-state energy balance between the generated power, the substrate-deposition thermal gradient, and a temperature dependent tool heat loss term: q tool (T) = a + b (T - 400°C) with a = 2.7 x 10 6 Wm -2 and b = 9.5 x 10 3 Wm -2 K -1 . The calibration indicates that about 69% of the generated heat is conducted into the tool for this configuration, which is much higher than previously reported. The calibrated heat-source is implemented in finite element software (Adamantine) to simulate the transient thermal history of a 100 cm 3 representative build in 8 min on a standard desktop (at 0.635 mm build-height resolution). For the first three layers, the substrate temperatures between simulation and experiment are within 10% mean absolute percentage error. Sensitivity analysis indicates that uncertainties in average deposition temperature and deformation localization (stir-zone geometry, depth, and spatial dependance of strain-rate and flow stress) dominate model variance, motivating additional experimental verification.
Additive Friction-Stir Deposition↗
Development, validation, and verification of multi-pass thermo-mechanical welding simulations using the open-source MOOSE framework: NeT TG4 benchmark weldment
This study develops and validates a sequentially coupled thermo-mechanical welding simulation for the three-pass 316L stainless steel NeT TG4 benchmark weldment using the open-source Multiphysics Object-Oriented Simulation Environment (MOOSE) and the Nuclear Engineering Material model Library (NEML). A diffused ellipsoidal heat source was calibrated against thermocouple data and weld macrographs to accurately model the fusion zone geometry and transient thermal fields. Material hardening is represented using the Lemaitre-Chaboche mixed isotropic-kinematic hardening model, while four annealing models - no annealing, single-stage at 1050 °C and 1300 °C, and two-stage at 800 °C/1300 °C - were implemented to assess the impact of annealing models on the accuracy of the predicted welding-induced plasticity, distortions, and residual stresses. The predictions were validated against experimental measurements and benchmarked against results from commercial software, demonstrating that thermo-mechanical MOOSE welding simulations achieve comparable accuracy with enhanced computational efficiency. This work highlights the potential of using open-source finite element frameworks like MOOSE for advanced manufacturing simulations.
Ji, Wendy [Australian Nuclear Science and Technolo↗
Infrared thermometry in high temperature materials processing: influence of liquid water and steam
Here, the capability of four infrared thermometry techniques (2-colour and 1-colour pyrometers, Pyrolaser and IR camera) was evaluated with respect to the impact of water or steam in the line of sight to determine temperature from two heat sources (blackbody calibration source and steel block inside the furnace). The influence of liquid water on the temperature readings was minimal when using 2-colour pyrometry due to comparable absorption coefficients of water for the measured wavelengths. The signals measured using both the Pyrolaser and the 1-colour pyrometer were decreased due to the partial absorption and resulted in an apparent temperature lower than the actual. Water readily absorbed the IR signal in the range of the IR camera operation, resulting in no signal whenever liquid water was present in the line of sight. Steam caused the most deviation and fluctuation of temperature readings for all techniques due to the large level of light scattering in addition to the absorption of the radiant energy. A technique was developed to determine the transmissivity (apparent emissivity) when water or steam is in the line of sight of measurement. An approximate correction to the measurements based on Planck’s law is discussed for both 2-colour and 1-colour pyrometers.
2-colour and 1-colour pyrometry↗
A Simulation Framework for Analyzing the Impact of Stochastic Occupant Behaviors on Demand Flexibility in Typical Commercial Buildings
As one of the primary users of the electric grid, buildings and building equipment, including heating, ventilation, and air conditioning (HVAC) systems, can be leveraged to provide the flexible demand needed to balance the grid. Typical strategies to achieve demand flexibility are to reduce electricity use during peak or critical periods by shutting down equipment or relaxing system setpoints, which will inevitably impact the occupants’ comfort. When occupants feel uncomfortable, they may take actions to regain their comfort, and some of those actions (such as turning on a personal fan) may have a negative impact on meeting the demand response goal. Therefore, it is important to incorporate occupant behaviors into the assessment ofthe building demand flexibility potential. In this study, a simulation framework that includes simulation of zone thermal loads, an HVAC system, and occupant behaviors, was developed to investigate the impact of occupant behaviors on demand flexibility. A case study was conducted using a small office model from the U.S. Department of Energy (DOE) Commercial Prototype Building Models to simulate the building envelope and zone loads. An agent-based occupant thermal behavior model was adapted to forecast occupants’ thermal comfort and their resulting thermal behaviors. An artificial neural network (ANN) based airflow model trained from a computational fluid dynamics (CFD) model of the zone was adopted to better predict the ambient environment of each occupant. An air-source heat pump simulation model that was calibrated from a real two-stage air-source heat pump system was used as the HVAC system. A typical load shedding event during peak hours was studied. Repeated simulations were conducted to capture the stochastic effects of occupant behaviors. The interplay between the demand flexibility, occupant comfort and behavior were analyzed by evaluating key performance indicators, including the energy use, occupant discomfort duration, and occupant behavior duration during the peak period. The results suggest that this framework can be used to analyze typical commercial buildings and their HVAC systems in terms ofdemand flexibility potential under the impact of occupant behaviors.
Chen, Zhelun↗
Infrared Camera Characterization of Bi-Propellant Reaction Control Engines during Auxiliary Propulsion Systems Tests at NASA's White Sands Test Facility in Las Cruces, New Mexico
This paper describes the application of a FUR Systems A40M infrared (IR) digital camera for thermal monitoring of a Liquid Oxygen (LOX) and Ethanol bi-propellant Reaction Control Engine (RCE) during Auxiliary Propulsion System (APS) testing at the National Aeronautics & Space Administration's (NASA) White Sands Test Facility (WSTF) near Las Cruces, New Mexico. Typically, NASA has relied mostly on the use of ThermoCouples (TC) for this type of thermal monitoring due to the variability of constraints required to accurately map rapidly changing temperatures from ambient to glowing hot chamber material. Obtaining accurate real-time temperatures in the JR spectrum is made even more elusive by the changing emissivity of the chamber material as it begins to glow. The parameters evaluated prior to APS testing included: (1) remote operation of the A40M camera using fiber optic Firewire signal sender and receiver units; (2) operation of the camera inside a Pelco explosion proof enclosure with a germanium window; (3) remote analog signal display for real-time monitoring; (4) remote digital data acquisition of the A40M's sensor information using FUR's ThermaCAM Researcher Pro 2.8 software; and (5) overall reliability of the system. An initial characterization report was prepared after the A40M characterization tests at Marshall Space Flight Center (MSFC) to document controlled heat source comparisons to calibrated TCs. Summary IR digital data recorded from WSTF's APS testing is included within this document along with findings, lessons learned, and recommendations for further usage as a monitoring tool for the development of rocket engines.
Holleman, Elizabeth↗
Increased accuracy and signal-to-noise ratio through recent improvements in infra-red video bolometer fabrication and calibration
The infra-red video bolometer (IRVB) is a diagnostic equipped with an infra-red camera that measures the total radiated power in thousands of lines of sight within a large field of view. Recently validated in MAST-U [Fderici et al., Rev. Sci. Instrum. 94, 033502 (2023)], it offers a high spatial resolution map of the radiated power in the divertor region, where large gradients are expected. The IRVB’s sensing element comprises a thin layer of high Z absorbing material, typically platinum, usually coated with carbon to reduce reflections [Peterson et al., Rev. Sci. Instrum. 79, 10E301 (2008)].Here, the possibility of using a relatively inert material such as titanium, is explored that can be produced in layers up to 1 μm compared to 2.5 μm for Pt and then coat it with Pt of the desired thickness (0.3 μm per side here) and carbon. This leads to a higher temperature signal (about 3 times) and better spatial resolution (about 4 times), resulting in higher accuracy in the measured power [Peterson et al., Rev. Sci. Instrum. 79, 10E301 (2008)]. This assembly is also expected to improve foil uniformity, as the Pt layer is obtained via deposition rather than mechanical processes [Mukai et al., Rev. Sci. Instrum. 87, 2014 (2016)].Given its multi-material composition, measuring the thermal properties of the foil assembly is vital. Various methods using a calibrated laser as a heat source have been developed, analyzing the temperature profile shape [Sano et al., Plasma and Fusion Res. 7, 2405039 (2012)] and [Mukai et al., Rev. Sci. Instrum. 89, 10E114 (2018)] or fitting the calculated laser power for different intensities and frequencies [Fderici et al., Rev. Sci. Instrum. 94, 033502 (2023)]. Here, a simpler approach is presented, which relies on analyzing the separate components of the foil heat equation for a single laser exposure in a given area. This can then be iterated over the entire foil to capture local deviations.
Magnetic Fusion Energy↗
Multi-fidelity thermal modeling of laser powder bed additive manufacturing
Laser powder bed fusion (LPBF) Additive manufacturing (AM) has attracted interest as an agile method of building production metal parts to reduce design-build-test cycle times for systems. However, predicting part performance is difficult due to inherent process variabilities. This makes qualification challenging. Computational process models have attempted to address some of these challenges, including mesoscale, full physics models and reduced fidelity conduction models. The goal of this work is credible multi-fidelity modeling of the LPBF process by investigating methods for estimating the error between models of two different fidelities. Two methods of error estimation are investigated, adjoint-based error estimation and Bayesian calibration. Adjoint-based error estimation is found to effectively bounding the error between the two models, but with very conservative bounds, making predictions highly uncertain. Bayesian parameter calibration applied to conduction model heat source parameters is found to effectively bound the observed error between the models for melt pool morphology quantities of interest. However, the calibrations do not effectively bound the error in heat distribution.
36 MATERIALS SCIENCE↗
Experimental Performance of a Micromachined Heat Flux Sensor
Steady-state and frequency response calibration of a microfabricated heat-flux sensor have been completed. This sensor is batch fabricated using standard, micromachining techniques, allowing both miniaturization and the ability to create arrays of sensors and their corresponding interconnects. Both high-frequency and spatial response is desired, so the sensors are both thin and of small cross-sectional area. Thin-film, temperature-sensitive resistors are used as the active gauge elements. Two sensor configurations are investigated: (1) a Wheatstone-bridge using four resistors; and (2) a simple, two-resistor design. In each design, one resistor (or pair) is covered by a thin layer (5000 A) thermal barrier; the other resistor (or pair) is covered by a thick (5 microns) thermal barrier. The active area of a single resistor is 360 microns by 360 microns; the total gauge area is 1.5 mm square. The resistors are made of 2000 A-thick metal; and the entire gauge is fabricated on a 25 microns-thick flexible, polyimide substrate. Heat flux through the surface changes the temperature of the resistors and produces a corresponding change in resistance. Sensors were calibrated using two radiation heat sources: (1) a furnace for steady-state, and (2) a light and chopper for frequency response.
TEMPERATURE SENSITIVE ELEMENTS↗
Development of heat flux sensors for turbine airfoils
The objectives of this program are to develop heat flux sensors suitable for installation in hot section airfoils of advanced aircraft turbine engines and to experimentally verify the operation of these heat flux sensors in a cylinder in a cross flow experiment. Embedded thermocouple and Gardon gauge sensors were developed and fabricated into both blades and vanes. These were then calibrated using a quartz lamp bank heat source and finally subjected to thermal cycle and thermal soak testing. These sensors were also fabricated into cylindrical test pieces and tested in a burner exhaust to verify heat flux measurements produced by these sensors. The results of the cylinder in cross flow tests are given.
Atkinson, William H.↗
Plutonium-238 Loadout Calorimeter Return To Service
The calorimeter in the transfer area in Building 7920 at the US Department of Energy’s Oak Ridge National Laboratory is used to measure the amount of 238 Pu in the Plutonium Heat Source Oxide. The calorimetry measurement is taken after the oxide is packaged in an ORISC (Oak Ridge Inner Shipping Capsule)/FSO (Fuel Storage Outer) assembly before loading into the Containment Vessel and shipping container. The equipment is used in three specific configurations: zero measurement (nothing in the sample cup), FSO measurement (actual measurement of 238 Pu), and reference calibration measurement (using the reference FSO as a known heat source). System checks were performed in July 2023 in preparation for scheduled material loadout. During these checks, personnel discovered that the reference FSO had experienced an electrical short in the heater cable and was no longer functional. The calorimeter was in the reference calibration measurement configuration at this time. Facility management was notified when the damage was discovered. The data from the Yokogawa recorder were pulled and analyzed for a span of time between September 2022 and July 2023. An unusual spike was found in the sample cup temperature data that started on October 19, 2022, and ended on October 20, 2022. The sample cup reached a temperature of 191.1°C. The maximum allowable temperature for the calorimeter thermopile to reach is 220°C based on the manufacturer statement provided in Appendix B of this report [1]. The calorimeter thermopile and the sample cup thermocouple are physically close to each other; therefore, the data suggest that the calorimeter itself never saw a temperature in excess of 191.1°C. Physical damage present on the cable, tape, and insulation suggests that the temperature reached a higher value in some locations within the sample cup than the data shows. Because of this discrepancy, testing of the calorimeter was required to confirm that the calorimeter is functioning the same as it was before the electrical short. The intent of this report is to assess the functionality of the calorimeter and determine if it is acceptable to use for 238 Pu loadout material measurement. Testing showed that the calorimeter is functionally equivalent to the initial calibration that was performed in the summer of 2021, and thus, the calorimeter was cleared to be used for its intended purposes.
46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
Fast response, blackbody furnace for temperatures up to 3000 deg k.
Inductively heated graphite furnace, having a source of blackbody radiation, for calibration of pyrometers up to 3,000 degrees k
PYROMETER↗
Sources of error in detonation calorimeters and error analysis for neat 2,4,6-triamino-1,3,5- trinitrobenzene (TATB)
Here, a calorimeter for measuring heats of detonation at Lawrence Livermore National Laboratory is described. A calibration precision of 0.2 % at the 95 % confidence interval (CI) is reported. Sources of uncertainty are discussed, including nonequivalent sources, which are those arising from differences between calibration and experimental tests. The systematic error due to nonequivalent sources is bounded to 0.19–0.22 % of the measured heat for a standard detonation test where the confinement material is gold. The recommendation is to correct for the systematic error by adding 0.19 % to the reported value and adding 0.03 % to the uncertainty. It is demonstrated that the precision of a detonation test is variable with testing duration because a source of uncertainty resides in the thermodynamic correction factor k6, which accounts for the contribution to heat by stirring; the generated power is additive and therefore highly impacted by total test time. The relative proportion also varies with the magnitude of heat release and sample size, adding variance to the weight of the error arising from the correction factor. A full error analysis based on the described sources of uncertainty is developed. The methodology is applied to a test series on neat 2,4,6-triamino-1,3,5- trinitrobenzene (TATB), demonstrating an ultimate precision of 0.7 % (single test) for materials testing and a relative standard deviation of 1.8 %.
47 OTHER INSTRUMENTATION↗
End-Use Savings Shapes Measure Documentation: Boiler Replacement with Air-Source Heat Pump Boiler and Electric Boiler Backup
Building on the successfully completed effort to calibrate and validate the U.S. Department of Energy's ResStock TM and ComStock TM models over the past three years, the objective of this work is to produce national data sets that empower analysts working for federal, state, utility, city, and manufacturer stakeholders to answer a broad range of analysis questions. The goal of this work is to develop energy efficiency, electrification, and demand flexibility end-use load shapes (electricity, gas, propane, or fuel oil) that cover a majority of the high-impact, market-ready (or nearly market-ready) measures. "Measures" refers to energy efficiency variables that can be applied to buildings during modeling. An end-use savings shape is the difference in energy consumption between a baseline building and a building with an energy efficiency, electrification, or demand flexibility measure applied. It results in a time-series profile that is broken down by end use and fuel (electricity or on-site gas, propane, or fuel oil use) at each timestep. ComStock is a highly granular, bottom-up model that uses multiple data sources, statistical sampling methods, and advanced building energy simulations to estimate the annual sub hourly energy consumption of the commercial building stock across the United States. The baseline model intends to represent the U.S. commercial building stock as it existed in 2018. The methodology and results of the baseline model are discussed in the final technical report of the End-Use Load Profiles project. This documentation focuses on a single end-use savings shape measure—boiler replacement by air-source heat pump boiler. This measure replaces space heating natural gas boilers by air-source heat pump boilers when applicable and helps quantify the decarbonization as well as the energy savings potential from the replacement. The measure resulted higher savings in natural gas consumption compared to the increase in electricity consumption, with a ratio of 2.9. The total natural gas energy consumption was reduced by 20%, whereas the total electricity consumption was increased by 2.5%.
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
End-Use Savings Shapes Measure Documentation: Boiler Replacement with Air-Source Heat Pump Boiler and Natural Gas Boiler Backup
Building on the successfully completed effort to calibrate and validate the U.S. Department of Energy's ResStock (™) and ComStock (™) models over the past three years, the objective of this work is to produce national data sets that empower analysts working for federal, state, utility, city, and manufacturer stakeholders to answer a broad range of analysis questions. The goal of this work is to develop energy efficiency, electrification, and demand flexibility end-use load shapes (electricity, gas, propane, or fuel oil) that cover a majority of the high-impact, market-ready (or nearly market-ready) measures. "Measures" refers to energy efficiency variables that can be applied to buildings during modeling. An end-use savings shape is the difference in energy consumption between a baseline building and a building with an energy efficiency, electrification, or demand flexibility measure applied. It results in a time-series profile that is broken down by end use and fuel (electricity or on-site gas, propane, or fuel oil use) at each timestep. ComStock is a highly granular, bottom-up model that uses multiple data sources, statistical sampling methods, and advanced building energy simulations to estimate the annual subhourly energy consumption of the commercial building stock across the United States. The baseline model intends to represent the U.S. commercial building stock as it existed in 2018. The methodology and results of the baseline model are discussed in the final technical report of the End-Use Load Profiles project. This documentation focuses on a single end-use savings shape measure - boiler replacement with air-source heat pump boiler with natural gas boiler backup. This measure replaces natural gas boilers for HVAC application by air-source heat pump boilers when applicable and use natural gas boiler backup when the heat pump boiler could not operate due to outdoor air conditions which are below its cutoff temperature. This measure helps to quantify the decarbonization as well as the energy savings potential from the replacement. The measure resulted higher savings in natural gas consumption compared to the increase in electricity consumption, with a ratio of 3. The total natural gas energy consumption was reduced by 41%, whereas the total electricity consumption was increased by 5.3%.
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
Probable age of Autolycus and calibration of lunar stratigraphy
Ar-39 - Ar-40 analyses of three petrographically distinct, shocked Apollo 15 KREEP (i.e., high K, rare earth element, P, and other trace element contents) basalt samples demonstrate that a major impact event affected all three samples at about 2.1 Ga. The Copernican System craters Aristillus and Autolycus are to the north. Autolycus, the older of the two, is in a particularly appropriate terrain and is the most likely source of the 2.1 Ga heating and delivery event. With this calibration point, and if Autolycus really is a Copernican crater, the Copernican System lasted twice as long as has previously been suggested. Furthermore, the moon was not subjected to a constant cratering rate over the past 3 billion years; the average rate in the preceding Eratosthenian must have been twice that in the Copernican.
Ryder, G.↗
Excitation of Na D-line radiation in collisions of sodium atoms with internally excited H2, D2, and N2
Excitation of D-line radiation in collisions of Na atoms with vibrationally excited N2, H2 and D2 was studied in two modulated crossed beam experiments. In both experiments, the vibrational excitation of the molecules was provided by heating the molecular beam source to temperatures in the range of 2000 to 3000 K, which was assumed to give populations according to the Boltzmann expression. In the first experiment, a total rate coefficient was measured as a function of molecular beam temperature, with absolute calibration of the photon detector being made using the black body radiation from the heated molecular beam source. Since heating affects both the internal energy and the collisional kinetic energy, the first experiment could not determine the relative contributions of internal energy transfer versus collisional excitation. The second experiment achieved partial separation of internal versus kinetic energy transfer effects by using a velocity-selected molecular beam. Using two simple models for the kinetic energy dependence of the transfer cross section for a given change in vibrational quantum number, the data from both experiments were used to determine parameters in the models.
Krause, H. F.↗