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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 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Thermal Performance of Neutron Sensor Qualification Device

The neutron sensor qualification device was developed to provide a temperature-controlled environment for neutron sensors and dosimetry, enabling irradiation in a neutron field at the Armed Forces Radiobiology Research Institute (AFRRI) TRIGA reactor facility. The device, constructed from low-activation and low neutron cross-section materials, features a modular tube furnace design with three independently controlled heating zones for controlling axial temperature distribution. Laboratory testing validated the device's thermal performance, including uniform temperature distribution with less than 6°C variation across the central region, a steady-state operational temperature of 350°C achieved in approximately 3 hours, and a cooling time constant of 3.5 hours. External surface temperatures remained safe for handling, with the surrounding aluminum structure remaining at ambient conditions. The results confirm the device’s suitability for neutron sensor qualification experiments, with potential for future operation at higher temperatures and further optimization of performance.

46 - INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AN↗
DOE OSTI2024

Conceptual Design of Neutron Sensor Qualification Device

The Advanced Sensors and Instrumentation Program at Idaho National Laboratory has been formulating strategies to qualify sensors for use in nuclear environments, particularly in irradiation experiments and advanced reactors. When qualifying neutron sensors for use in high-temperature environments, the wide range of neutron flux levels and representative energy spectra presents significant challenges. This paper discusses the development of the Neutron Sensor Qualification Device (NQD), which is designed to test neutron sensors in high temperature controlled environments with known neutron spectra, addressing the spatial and spectral complexities of neutron fluxes in reactor cores. The proposed NQD will be situated in the exposure room at the Armed Forces Radiobiology Research Institute, thus affording a unique capability to expose sensors to high neutron and gamma fluxes. To achieve thermal control, the device will utilize a radiation-hardened tube furnace, accommodating multiple sensors and neutron activation dosimetry wires. Titanium, iron, and cobalt dosimeter wires are chosen from the American Society for Testing and Materials and International Reactor Dosimetry and Fusion File libraries as references for providing energy-dependent fluence measurements. The design ensures precise sensor positioning to minimize mutual shielding and flux perturbation, which are evaluated via Monte Carlo N particle Transport Code (MCNP) simulations. These simulations have informed the development of guidelines on sensor placement within the NQD. The NQD is essential to the qualification of neutron sensors for advanced reactor technologies. It enables controlled testing of a statistically significant number of sensors, thereby supporting assessments of sensor performance across various neutron flux levels and temperatures. This paper highlights the detailed planning for the NQD prototype, along with its inaugural irradiation (scheduled for fiscal year [FY] 2025). The results from this initial testing will be fundamental in evaluating the device’s performance and establishing measurement uncertainty for in-pile neutron sensor measurements.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2024

Laboratory Testing of the Temperature Sensor Qualification Device

The Temperature sensor Qualification Device (TQD) has been developed and tested under laboratory conditions to evaluate its thermal performance and the reliability of its retractable sensor system. The TQD is designed to provide an isothermal environment for temperature sensors in both test and reference zones during irradiation experiments. Initial testing revealed minimal radial and azimuthal temperature variations but identified a significant axial gradient. To address this, design modifications were implemented, including enhanced insulation and the addition of a small heater at the device's top. These changes are expected to produce a more uniform axial temperature profile, though further testing is recommended prior to irradiation. The retractable sensor mechanism was rigorously tested, achieving 1,350 cycles at room temperature and 332 cycles at 400°C before failure. The primary failure mechanism was the thermocouple becoming stuck in the wire guide or capillary tube. Based on these results, design improvements were proposed, such as incorporating a load cell for force monitoring and a stepper motor for precise sensor positioning.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2024

Sensor Qualification for the Development of Advanced Reactors

A temperature sensor qualification device is undergoing development and testing in order to qualify temperature sensors for advanced reactor metrology applications. This device will provide National Institute of Standards and Technology (NIST) traceable performance testing of temperature sensors while under the high radiation environments experienced while in-core. This is completed by utilizing retractable sensors which transfer the measurements from ex-core to in-core sensors. A detailed discussion of the uncertainty propagation associated with this comparative process is provided. Experimental testing of the temperature distribution occurring in the device has begun and is reported on. It is pertinent to minimize this temperature distribution to prevent variation in sensor measurements. This variation will be indistinguishable from sensor drift for in-pile applications and would result in unnecessarily conservative uncertainty bounds.

46 - INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AN↗
DOE OSTI2024

Robustness and printed sensor qualification

A limiting factor of additive manufactured (AM) sensors for in-pile applications is the development of appropriate interconnection and packaging strategies that can maintain reliable performance in extreme environments. Failure mechanisms in these harsh conditions could include, but not limited to, materials interaction (i.e., intermetallic formation) and coefficient of thermal expansion (CTE) mismatch between the individual components of the sensors. To mitigate premature failure and enable the successful sustained operation of AM sensors, non-destructive qualification tests are used as an intermediate process control step used for verifying robustness and reliability of the sensor before they are deployed. A materials system of interest is the use of barium strontium titanium oxide (BST) films on stainless steel 316L (SS316L) substrate. Due to BST’s high dielectric constant and tunable dielectric properties, there is an interest for its application as an insulation/encapsulation layer for capacitive strain gauges when printed on structural materials. Previous work on the BST/SS316L material system, however, showed that the BST cracks when exposed to temperatures up to 600 °C due to CTE mismatch between the printed BST film and the metallic substrate. When comparing different fabrication techniques, less surface cracking was observed in the samples that deposited thinner (i.e., 2-20 μm) than samples that were thicker (i.e., 135 µm – 300 µm). The objective of this report is to establish a qualification process that will determine and address any challenges (i.e., mechanical failure of thick prints) of the AM sensor prior to its application in experimental tests. To demonstrate the qualification process in this report, laser spallation and uniaxial tensile tests using dynamic and quasi-static loading, respectively, will be discussed.

36 - MATERIALS SCIENCE↗
DOE OSTI2023

Neutron irradiation and electrical characterisation of the first 8” silicon pad sensor prototypes for the CMS calorimeter endcap upgrade

As part of its HL-LHC upgrade program, the CMS collaboration is replacing its existing endcap calorimeters with a high-granularity calorimeter (CE). The new calorimeter is a sampling calorimeter with unprecedented transverse and longitudinal readout for both electromagnetic and hadronic compartments. Due to its compactness, intrinsic time resolution, and radiation hardness, silicon has been chosen as active material for the regions exposed to higher radiation levels. The silicon sensors are fabricated as 20 cm (8”) wide hexagonal wafers and are segmented into several hundred pads which are read out individually. As part of the sensor qualification strategy, 8” sensor irradiation with neutrons has been conducted at the Rhode Island Nuclear Science Center (RINSC) and followed by their electrical characterisation in 2020-21. The completion of this important milestone in the CE's R&D program is documented in this paper and it provides detailed account of the associated infrastructure and procedures.The results on the electrical properties of the irradiated CE silicon sensors are presented.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2023

Printed Strain Gauges for High Temperature Applications (>300°C)

The real-time understanding of strain and deformation of materials provides prognostic health monitoring of components of current operational reactors and valuable data that shortens the timeline for the development of new nuclear-relevant materials in test reactor experiments. This report discusses the current development and testing of additively manufactured strain gauges. This has potential to improve the sensor design and manufacturing techniques to meet the requirements of the current and advanced nuclear reactors (i.e., in terms of environment conditions, sample geometry, and materials compatibility). The developmental additively manufactured strain gauges are exposed to separate effects testing (i.e., mechanical strain, high temperature) to determine environmental factors that affect the strain gauge. In addition, sensor qualification methodologies are further developed for determining the reliability and robustness at the interface of the AM strain gauge materials.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Application of printed strain gauges in prototypical nuclear reactor conditions

This report discusses the current development and testing of additively manufactured temperature sensors and resistive/ capacitive strain gauges. This has potential to improve the sensor design and manufacturing techniques to meet the requirements of in-pile monitoring of mechanical properties and structural health of materials and specimens in current and advanced nuclear test reactors (i.e., in terms of environment conditions, sample geometry, and materials compatibility). The developmental additively manufactured strain gauges are exposed to separate effects testing (i.e., mechanical strain (up to 1000 µe), high temperature (up to 700 °C)) to determine environmental factors that affect the performance of the strain gauge. The robustness and integrity of a printed strain gauge layer exposed to a molten salt environment for up to 500 hours was evaluated, with the goal of assessing material compatibility of printed strain sensors for instrumented surveillance test articles in molten salt reactors. In addition, sensor qualification methodologies are further developed for determining the reliability and robustness at the interface of the additively manufactured strain gauge materials.

36 - MATERIALS SCIENCE↗
DOE OSTI2023

Testing Instrument Extremes in the TREAT Facility

TREAT is a transient power-shaping reactor whose primary mission is to enhance safety performance by testing nuclear fuels and materials under thermodynamic and neutronic conditions ranging from off-normal to extreme. Transient testing of nuclear fuels is analogous to car crash testing, in that the dramatic changes commonly seen when comparing the test specimens' initial and final state points necessitate in-situ measuring in order to interpret and understand the evolution of the experiment. TREAT’s experiment design strategy utilizes a highly reconfigurable and accessible reactor core that affords flexibility when installing experiment devices, thanks to the lack of a primary coolant boundary and the inclusion of multiple access points in the reactor bioshield. Within the experiment devices, the test specimens (which are integrated with their test environments), desired instrumentation diagnostics, and safety considerations are all contained in a single engineered package. The experiments encompass various types of environments (e.g., water, sodium, and gas at temperature and pressure), as well as a range of control options (e.g., static or flowing coolants). The experimental conditions are uniquely representative of advanced reactors, providing challenges to sensor performance but also affording a unique opportunity for development and qualification of sensors suited to these environments.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2022

Assessment of ASI-developed Sensors for Inclusion in METL Testing

The Advanced Sensors and Instrumentation (ASI) program facilitates the development of new sensors for both conventional and advanced reactors. Advanced reactor concepts utilize coolants other than light water, such as molten salts, liquid sodium, and high-temperature helium. Qualification of sensors developed for these advanced reactors is complicated by the relatively small number of facilities available that can provide relevant testing conditions (e.g., temperature, flow, and coolant chemistry). This report identifies sensors that were developed under the ASI program and may be tested in one available testbed: the Mechanisms Engineering Test Loop (METL) at Argonne National Laboratory (ANL), a non-nuclear liquid sodium flow facility.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2023

Evaluation of HPK n + - p planar pixel sensors for the CMS Phase-2 upgrade

To cope with the challenging environment of the planned high luminosity upgrade of the Large Hadron Collider (HL-LHC), scheduled to start operation in 2029, CMS will replace its entire tracking system. The requirements for the tracker are largely determined by the long operation time of 10 years with an instantaneous peak luminosity of up to 7.5 × 10 34 cm –2 s –1 in the ultimate performance scenario. Depending on the radial distance from the interaction point, the silicon sensors will receive a particle fluence corresponding to a non-ionizing energy loss of up to $\Phi_{\text {eq}}$ = 3.5 × 10 16 cm –2 . Here this paper focuses on planar pixel sensor design and qualification up to a fluence of $\Phi_{\text {eq}}$ = 1.4 × 10 16 cm –2 . For the development of appropriate planar pixel sensors an R&D program was initiated, which includes $n^+ -p$ sensors on 150 mm (6”) wafers with an active thickness of 150 μm with pixel sizes of 100 × 25 μm 2 and 50 × 50 μm 2 manufactured by Hamamatsu. Single chip modules with ROC4Sens and RD53A readout chips were made. Irradiation with protons and neutrons, as well was an extensive test beam campaign at DESY were carried out. This paper presents the investigation of various assemblies mainly with ROC4Sens readout chips. It demonstrates that multiple designs fulfill the requirements in terms of breakdown voltage, leakage current and efficiency. The single point resolution for 50 × 50 μm 2 pixels is measured as 4.0 μm for non-irradiated samples, and 6.3 μm after irradiation to $\Phi_{\text {eq}}$ = 7.2 × 10 15 cm –2 .

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2022

ATLAS ITk strip sensor quality control procedures and testing site qualification

Abstract The high-luminosity upgrade of the Large Hadron Collider, scheduled to become operational in 2029, requires the replacement of the ATLAS Inner Detector with a new all-silicon Inner Tracker. Radiation hard n + -in-p micro-strip silicon sensors were developed by the ATLAS Inner Tracker strip collaboration and are produced by Hamamatsu Photonics K.K. Production of the total amount of 22000 strip sensors has started in 2020 and will continue until 2025. The ATLAS strip sensor collaboration has the responsibility to monitor the quality of the fabricated devices by performing detailed measurements of individual sensor characteristics and by comparing the obtained results with the tests done by the manufacturer. Dedicated Quality Control procedures were developed to check whether the delivered large-format sensors adhere to the ATLAS specifications. The institutes performing the Quality Control testing of the pre-production and production ATLAS ITk strip sensors had to initially be qualified for multiple high-throughput tests by successfully completing the Site Qualification process. The Quality Control procedures and the qualification process are described in this paper.

Instruments & Instrumentation↗
DOE OSTI2025

Demonstrating Advanced Sensors for In-Situ Monitoring Towards Qualification of Nuclear Relevant Components

The U.S. Department of Energy’s Office of Nuclear Energy Advanced Materials and Manufacturing Technologies (AMMT) program is pursuing qualification of laser powder bed fusion (LPBF) components for nuclear applications. A major focus of this effort is the use of in situ process monitoring and machine learning–based tools to establish real-time quality assurance. The primary objective of this report is to identify and evaluate the most relevant in situ sensor systems for LPBF, and to document the deployment of these systems across platforms critical to the AMMT program. This work demonstrates how in situ monitoring can detect process anomalies, track geometry-dependent flaws, and identify limiting combinations of processing parameters—particularly those related to energy density and complex geometries (e.g., overhanging structures). To support this goal, a diverse suite of sensor modalities was evaluated across LPBF platforms, including visible and near-infrared (NIR) imaging, fringe projection profilometry, long-wavelength infrared (LWIR) thermography, and high-speed photodiode/pyrometry systems. These sensor streams were integrated with Peregrine, a machine-agnostic software platform that, among other capabilities, can generate real-time process anomaly classification. This report documents sensor deployments on multiple AMMT flagship platforms, including the Concept Laser M2 and Renishaw AM400/AM250 systems. Calibration builds with complex, flaw-prone geometries such as unsupported overhangs, stepped features, and thin walls, were used to evaluate how well Peregrine and its associated sensors could detect process anomalies and other instabilities under varied energy densities. It will be shown how Peregrine reliably identifies common process anomalies such as recoater streaking, superelevation, etc., and can be used in post-build analysis for anomaly spatial distributions throughout the build height to better understand the impact of geometry and processing parameter choice on the build. This work demonstrates measurable progress toward the vision that components can be born-qualified by establishing a real-time monitoring framework, identifying limiting process conditions, and laying the foundation for sensor fusion–enabled prediction pipelines that are scalable across platforms and applicable to nuclear-relevant components.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Testing, Calibration, and UxS Integration of the Kromek GR1 Plus CZT Gamma Spectrometer

Collecting radiation measurements can be a hazardous task, especially in the presence of highly active sources. Various scenarios necessitate source search, classification, and quantification, often with limited or no a priori information. Activities such as disaster mitigation, emergency response, environmental monitoring, and site remediation may involve dangerous radioactive sources. In these situations, there is a pressing need for remote monitoring capabilities that protect human operators from potential harm and enhance adherence to the principle of “As Low as Reasonably Achievable” (ALARA) for radiation doses. The first step toward achieving remote radiation measurement capabilities is the remote operation of a radiation sensor. Once this milestone is reached, the next challenge is to integrate this remote sensing capability into suitable actuation agents, collectively referred to as uncrewed systems (UxS). These systems include familiar platforms such as robotic quadrupeds, aerial multirotor vehicles, and ground vehicles, any of which may be teleoperated, act autonomously, or utilize a combination of both. A critical factor in achieving remote radiation sensing is the availability of data from the appropriate sensor. Many commercially available radiation sensors have closed-source documentation for their communication protocols. Typical end-user products are often self-contained, handheld devices designed for manual measurement scenarios. While there are commercial off-the-shelf (COTS) integrations of radiation sensors with UxS available for purchase, these solutions are typically tailored for specific use cases and may not meet the requirements of different applications. This paper discusses efforts to remotely acquire radiation measurements from a small form-factor CZT gamma spectrometer. Sandia National Laboratories has successfully demonstrated the initial capability to integrate low size, weight, and power (SWaP) gamma spectroscopy into various UxS, alongside co-located GPS data logging and sensor calibration and qualification. With remote gamma spectroscopy achieved, the stage is set for UxS integration of this capability.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2024

High Yield Xray Imager Final Design Review

The High Yield Xray Imager (HYXI) is a new NIF target diagnostic system currently under development. The goal of HYXI is to provide high-fidelity, high temporal resolution x-ray imaging capability on high yield NIF implosions at 10MJ and above. The HYXI instrument design concept is based on the combination of two technologies that have been successfully utilized at the NIF on previous instruments, electron pulse-dilation and hybrid-CMOS sensor imaging. The combination of these two techniques will give HYXI sufficient data quality to ascertain differences in hot spot formation dynamics between high and low yield implosions. This information will highlight the critical hot spot conditions needed for ignition and burn. The HYXI design leverages the successful operation of the PDIXI x-ray imager at the NIF on multi MJ yield shots. A new radiation tolerant CMOS imaging array (HYPERION) is being developed to eliminate the significant background noise which limits the data quality of PDIXI. We successfully placed the contract with Advanced hCMOS Systems (AHS) to develop the HYPERION sensor, which fulfils our criteria to place long lead time item procurements by end of FY24. The HYXI Final Design Review was completed at the end of Q4 FY24 (Sep 24 th and Sep 30 th ). The HYXI project is a multi-year effort with a phased approach to be bring up system functionality over time in parallel with the development and fabrication effort of the HYPERION CMOS imaging array. In Phase 1, time-integrated x-ray images on NIF DT experiments will be collected starting in Q3 FY25. In Phase 2 of the project, time-resolved imaging with HYXI utilizing a spare microchannel plate detector back-end will begin in Q3 FY26. Phase 3 concludes the project with the installation of the HYPERION sensor array and the final performance qualification of the HYXI instrument which is scheduled for Q3 FY27 as discussed in the PDR and MRT report on this project in FY23.

42 ENGINEERING↗
DOE OSTI2023

A Data-Driven Framework for Direct Local Tensile Property Prediction of Laser Powder Bed Fusion Parts

This article proposes a generalizable, data-driven framework for qualifying laser powder bed fusion additively manufactured parts using part-specific in situ data, including powder bed imaging, machine health sensors, and laser scan paths. To achieve part qualification without relying solely on statistical processes or feedstock control, a sequence of machine learning models was trained on 6299 tensile specimens to locally predict the tensile properties of stainless-steel parts based on fused multi-modal in situ sensor data and a priori information. A cyberphysical infrastructure enabled the robust spatial tracking of individual specimens, and computer vision techniques registered the ground truth tensile measurements to the in situ data. The co-registered 230 GB dataset used in this work has been publicly released and is available as a set of HDF5 files. The extensive training data requirements and wide range of size scales were addressed by combining deep learning, machine learning, and feature engineering algorithms in a relay. The trained models demonstrated a 61% error reduction in ultimate tensile strength predictions relative to estimates made without any in situ information. Lessons learned and potential improvements to the sensors and mechanical testing procedure are discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Integration of sensors through additive manufacturing leading to increased efficiencies of gas turbines for power generation and propulsion

To realize the full capability of additively manufactured components in complex energy systems, it is imperative to minimize early component failures during development phases and during operation. Traditional field feedback timelines and offline inspection protocols significantly reduce the design-manufacturing iteration times. To address this specific question, the project developed and demonstrated a method for the integration of sensors into complex components through additive manufacturing. The team used gas turbine engines as a platform, which meets the need of both power generation and propulsion and offer opportunities for cost reductions and efficiency increases. The innovation of this intelligent integration of sensors into complex components uniquely customized to address questions of integrity and durability for additively manufactured components. With real-time sensing data from additively manufactured components, turbine manufacturers will realize higher efficiencies, reduced component failures, and a 30-50% acceleration in product deployment of high efficiency gas turbine components due to a faster reduction in component risk assessment under actual operating conditions. This is a transformative shift towards a data-driven design and qualification of additively manufactured gas turbine components. To directly integrate sensors into additively manufactured components with all the complexities of actual hardware, powder bed fusion (direct metal laser sintering) and laser metal deposition technologies was developed. Validation took take place in two university laboratories both of which contain actual engine hardware and closely simulate a gas turbine prior to demonstrating the technology in a turbine development test. Indeed, two major technologies from this research cold impact turbine systems in the near future: (1) higher efficiency materials and designs enabled by additive manufacturing with 50% faster design to manufacturing cycle time, to enable faster time-to-market targets; and (2) integration of sensors into additively manufactured components enabling broad health and condition based prognostics for faster component and engine risk reduction.

33 ADVANCED PROPULSION SYSTEMS↗