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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 OSTI2016

New figuring model based on surface slope profile for grazing-incidence reflective optics

Surface slope profile is widely used in the metrology of grazing-incidence reflective optics instead of surface height profile. Nevertheless, the theoretical and experimental model currently used in deterministic optical figuring processes is based on surface height, not on surface slope. This means that the raw slope profile data from metrology need to be converted to height profile to perform the current height-based figuring processes. The inevitable measurement noise in the raw slope data will introduce significant cumulative error in the resultant height profiles. As a consequence, this conversion will degrade the determinism of the figuring processes, and will have an impact on the ultimate surface figuring results. To overcome this problem, an innovative figuring model is proposed, which directly uses the raw slope profile data instead of the usual height data as input for the deterministic process. In this article, first the influence of the measurement noise on the resultant height profile is analyzed, and then a new model is presented; finally a demonstration experiment is carried out using a one-dimensional ion beam figuring process to demonstrate the validity of our approach.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Comparison of Optical Modelling Tools for Sunshape and Surface Slope Error

The sunshape and mirror surface slope error are two main factors that influence the characteristics of incoming and reflected solar beams in a solar concentrator. Different optical modelling tools, however, address these two factors with different methods and simplifications. In this study, simulation methods are reviewed in five optical modelling tools, namely SolTrace, Tonatiuh, Tracer, Heliosim and SolarPILOT. A series of simple test cases are simulated in each tool to compare and verify the implementation of sunshape and slope error models separately. This strategy has successfully identified discrepancies among the tools and contributed to a better understanding of their reasons. It has also uncovered few glitches in some of those tools and contributed to improve them. It is our hope that this study will help to resolve common misconceptions, to build confidence amongst CSP researches on the accuracy of tools with which they have less experience, and to ensure better agreement in optical modelling work in future.

14 SOLAR ENERGY↗
DOE OSTI2020

Super-resolution surface slope metrology of x-ray mirrors

We present experimental, analytical, and numerical methods developed for reconstruction (deconvolution) of one-dimensional (1D) surface slope profiles over the spatial frequency range where the raw data are significantly perturbed due to the limited resolution of the measurement instrument. We characterize the spatial resolution properties of a profiler with the instrument's transfer function (ITF). To precisely measure the ITF, we apply a recently developed method utilizing test surfaces with 1D linear chirped height profiles of constant slope amplitude. Based on the results of the ITF calibration, we determine parameters of an analytical model for the ITF that is used in the original reconstruction software. Here, we treat surface slope metrology data obtained with the Optical Surface Measuring System (OSMS), using as a sensor an electronic autocollimator (AC) ELCOMAT-3000. The spatial resolution of the OSMS is limited by the size of the AC light-beam-collimating aperture. For the purposes of this investigation, the OSMS is equipped with a circular aperture with a diameter of 2.5 mm. This is a typical arrangement of most AC-based slope profilers developed for surface slope metrology of state-of-the-art x-ray mirrors. Using the example of surface slope metrology of two state-of-the-art elliptically shaped x-ray focusing mirrors, we demonstrate that the developed data reconstruction procedure allows us to significantly improve the accuracy of surface slope metrology with the OSMS over the spatial wavelength range from ~1.6 mm to 7 mm. Thus, the amplitude of the quasi-periodic error characteristic of the deterministic polishing process used appears to be higher by a factor of~2 than is apparent from the rough metrology data. Underestimation of the surface slope errors in this spatial wavelength range can lead to serious errors in the expected performance of x-ray mirrors in synchrotron beamlines, especially at modern light sources utilizing coherent x rays, where the perturbations can lead to increased speckle-like intensity variation.

47 OTHER INSTRUMENTATION↗
DOE OSTI2019

Verification of optical modelling of sunshape and surface slope error for concentrating solar power systems

Sunshape and reflector surface slope error distributions are significant elements in modelling the optical behaviour of a concentrating solar power system. Different optical modelling tools implement these elements with various approaches. Discrepancies can easily accumulate in simulations of a large optical system as a result of incorrect implementations. This study reviews and verifies the implementations of these two factors in six tools that are widely used for optical modelling in solar energy research: Tonatiuh, SolTrace, Tracer, Solstice, Heliosim and SolarPILOT. The review incorporates three rounds of tests. Firstly, basic tests examine each factor carefully in simplified on-axis reflector-target configurations (round 'A'). Secondly, off-axis effects are introduced (round 'B'). Thirdly, full heliostat field simulations are verified (round 'C'). All of the test cases are simulated with each modelling tool, and results are compared. Discrepancies were observed due to approximations inherent in the cone optics (convolution) methods, incorrect implementation the of pillbox slope errors, different approaches to setting the circumsolar ratio for the Buie sunshape, and different approaches to the calculation of blocking and shading losses in some tools. All issues are discussed fully, and solutions to most issues were implemented within the scope of the present study. Some remaining issues are noted. The study highlights the importance of careful implementation of these aspects of optical modelling and contributes to an improvement in the quality of several widely-used tools.

14 SOLAR ENERGY↗
DOE OSTI2019

Investigation on lateral resolution of surface slope profilers

Here, we investigate and compare the spatial (lateral) resolution, or more generally, the optical/instrumental transfer function (OTF/ITF) of surface slope measuring profilometers of two different types that are commonly used for high accuracy characterization of x-ray optics at the long-spatial-wavelength range. These are an autocollimator based profiler, Optical Surface Measuring System (OSMS), and a long trace profiler, LTP-II, both available at the Advanced Light Source (ALS) X-Ray Optics Lab (XROL). In the OSMS, an ELCOMAT-3000 electronic auto-collimator, vertically mounted to the translation carriage and equipped with an aperture of 2.5 mm diameter, is scanned along the surface under test. The LTP-II OTF has been measured for two different configurations, a classical two-beam pencil-beam-interferometry and a single-Gaussian-beam deflectometry. For the ITF calibration, we apply a recently developed method based on test surfaces with one-dimensional (1D) linear chirped height profiles of constant slope amplitude. Analytical expressions for the OTFs, empirically deduced based on the experimental results, are presented. We also discuss the application of the results of the ITF measurements and modeling to improve the surface slope metrology with state-of-the-art x-ray mirrors.

42 ENGINEERING↗
DOE OSTI2019

Transfer of autocollimator calibration for use with scanning gantry profilometers for accurate determination of surface slope and curvature of state-of-the-art x-ray mirrors

X-ray optics, desired for beamlines at free-electron-laser and diffraction-limited-storage-ring x-ray light sources, must have almost perfect surfaces, capable of delivering light to experiments without significant degradation of brightness and coherence. To accurately characterize such optics at an optical metrology lab, two basic types of surface slope profilometers are used: The long trace profilers (LTPs) and nanometer optical measuring (NOM) like angular deflectometers, based on electronic autocollimator (AC) ELCOMAT-3000. The inherent systematic errors of the instrument's optical sensors set the principle limit to their measuring performance. Where autocollimator of a NOM-like profiler may be calibrated at a unique dedicated facility, this is for a particular configuration of distance, aperture size, and angular range that does not always match the exact use in a scanning measurement with the profiler. Here we discuss the developed methodology, experimental set-up, and numerical methods of transferring the calibration of one reference AC to the scanning AC of the Optical Surface Measuring System (OSMS), recently brought to operation at the ALS Xray Optics Laboratory. We show that precision calibration of the OSMS performed in three steps, allows us to provide high confidence and accuracy low-spatial-frequency metrology and not â€print into' measurements the inherent systematic error of tool in use. Here, with the examples of the OSMS measurements with a state-of-The-Art x-ray aspherical mirror, available from one of the most advanced vendors of X-ray optics, we demonstrate the high efficacy of the developed calibration procedure. The results of our work are important for obtaining high reliability data, needed for sophisticated numerical simulations of beamline performance and optimization of beamline usage of the optics. This work was supported by the U. S. Department of Energy under contract number DE-AC02-05CH11231.

47 OTHER INSTRUMENTATION↗
DOE OSTI2018

Modeling Discrete Forest Anisotropic Reflectance Over a Sloped Surface With an Extended GOMS and SAIL Model

Topographic effects on canopy reflectance play a pivotal role in the retrieval of surface biophysical variables over rugged terrain. In this paper, we proposed a new canopy anisotropic reflectance model for discrete forests, Geometric Optical and Mutual Shadowing and Scattering-from-Arbitrarily-Inclined-Leaves model coupled with Topography (GOSAILT), which considers the effects of slope, aspect, geotropic nature of tree growth, multiple scattering, and diffuse skylight. GOSAILT-simulated areal proportions of four scene components (i.e., sunlit crown, shaded crown, sunlit background, and shaded background) were evaluated using the Geometric Optical model for Sloping Terrains (GOST) model. The canopy reflectances simulated by GOSAILT were validated against two reflectance data sets: Discrete anisotropic radiative transfer (DART) simulations and wide-angle infrared dual-model line/area array scanner (WIDAS) observations. Compared with a horizontal surface, the forest canopy reflectance over a steep slope (60°) is significantly distorted with absolute (relative) bias values of 0.048 (79.60%) and 0.056 (12.02%) for the red and near-infrared (NIR) bands, respectively. The GOSAILT-simulated component areal proportions show close agreements with GOST. Moreover, GOSAILT simulations have high overall accuracy (red band: coefficient of determination (R²) = 0.96; root-mean-square error (RMSE) = 0.003; and mean absolute percentage error (MAPE) = 3.91%; and NIR band: R² = 0.78, RMSE = 0.019; MAPE = 3.94%) when compared with the DART simulations. In conclusion, these extensive validations indicate good performances of GOSAILT in canopy reflectance simulations over sloped surfaces.

58 GEOSCIENCES↗
DOE OSTI2020

Multifunctional light beam source for surface slope measuring long trace profilers

To fully exploit the advantages of fourth-generation synchrotron light sources, diffraction-limited-storage-rings (DLSR) and fully coherent free electron lasers (FELs), beamline mirrors and diffraction grating must be of exceptional quality. To achieve the required mirror and grating quality, the metrology instrumentation and methods used to characterize these challenging optics and, even more so, optical assemblies must also offer exceptional functionality and performance. One of the most widely used slope measuring instruments for characterizing x-ray optics is the long trace profiler (LTP). The easily reconfigurable mechanical design of the LTP allows optimization of the profiler arrangement to the specifics of a particular metrology task. Here, we discuss the optical schematic, design, and performance of an original multifunctional light beam source that provides functional flexibility of the LTP optical sensor. With this source, the LTP can be easily reconfigured for measurements of x-ray mirrors or diffraction gratings that have widely different source coherence requirements. Usage of a source with a low degree of coherence for mirror metrology helps to suppress the LTP systematic errors due to spurious interference effects in the LTP optical elements. A high-coherence narrow-band source is used for groove-density-distribution characterization of x-ray diffraction gratings. The systematic error and spatial resolution of the LTP with the different sources is also measured and analyzed.

Yashchuk, Valeriy V.↗
DOE OSTI2018

Revealing particle-scale powder spreading dynamics in powder-bed-based additive manufacturing process by high-speed x-ray imaging

Powder spreading is a key step in the powder-bed-based additive manufacturing process, which determines the quality of the powder bed and, consequently, affects the quality of the manufactured part. However, powder spreading behavior under additive manufacturing condition is still not clear, largely because of the lack of particle-scale experimental study. Here, we studied particle-scale powder dynamics during the powder spreading process by using in-situ high-speed high-energy x-ray imaging. Evolution of the repose angle, slope surface speed, slope surface roughness, and the dynamics of powder clusters at the powder front were revealed and quantified. Interactions of the individual metal powders, with boundaries (substrate and container wall), were characterized, and coefficients of friction between the powders and boundaries were calculated. The effects of particle size on powder flow dynamics were revealed. Here, the particle scale powder spreading dynamics, reported here, are important for a thorough understanding of powder spreading behavior in the powder-bed-based additive manufacturing process, and are critical to the development and validation of models that can more accurately predict powder spreading behavior.

42 ENGINEERING↗
DOE OSTI2021

Systems and methods of electrolytic production of aluminum

In some embodiments, an exemplary electrolytic cell includes: a cathode structure disposed within an electrolysis cell, wherein the electrolysis cell is configured to produce metal on a surface of the cathode structure, wherein the cathode structure is configured to fit along a floor of the electrolysis cell, wherein the cathode structure has a sloped surface when compared to a generally horizontal plane, and wherein via the sloped surface, the cathode structure is configured to drain a metal product from the sloped surface towards a lower end of the cathode structure.

Liu, Xinghua↗
DOE OSTI2018

Sandia Optical Fringe Analysis Slope Tool (SOFAST) v. 2018.11.20

SOFAST is used to characterize the surface slope of reflective mirrors for solar applications. SOFAST uses a large monitor or projection screen to display fringe patterns, and a machine vision camera to image the reflection of these patterns in the subject mirror. From these images, a detailed map of surface normals can be generated and compared to design or fitted mirror shapes. SOFAST uses standard Fringe Reflection (Deflectometry) approaches to measure the mirror surface normals. SOFAST uses an extrinsic analysis of key points on the facet to locate the camera and monitor relative to the facet coordinate system. It then refines this position based on the measured surface slope and integrated shape of the mirror facet. The facet is placed into a reference frame such that key points on the facet match the design facet in orientation and position. This is key to evaluating a facet as suitable for a specific solar application. SOFAST reports the measurements of the facet as detailed surface normal location in a format suitable for ray tracing optical analysis codes. SOFAST also reports summary information as to the facet fitted shape (monomial) and error parameters. Useful plots of the error distribution are also presented.

Yellowhair, Julius↗
DOE OSTI2023

Hybrid height and slope figuring method for grazing-incidence reflective optics

Grazing-incidence reflective optics are commonly used in synchrotron radiation and free-electron laser facilities to transport and focus the emitted X-ray beams. To preserve the imaging capability at the diffraction limit, the fabrication of these optics requires precise control of both the residual height and slope errors. However, all the surface figuring methods are height based, lacking the explicit control of surface slopes. Although our preliminary work demonstrated a one-dimensional (1D) slope-based figuring model, its 2D extension is not straightforward. In this study, a novel 2D slope-based figuring method is proposed, which employs an alternating objective optimization on the slopes in the x - and y -directions directly. An analytical simulation revealed that the slope-based method achieved smaller residual slope errors than the height-based method, while the height-based method achieved smaller residual height errors than the slope-based method. Therefore, a hybrid height and slope figuring method was proposed to further enable explicit control of both the height and slopes according to the final mirror specifications. An experiment to finish an elliptical-cylindrical mirror using the hybrid method with ion beam figuring was then performed. Both the residual height and slope errors converged below the specified threshold values, which verified the feasibility and effectiveness of the proposed ideas.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Improvements in Reflected Target Non-intrusive Assessment (ReTNA)

Accurate optical surfaces are a primary driver of concentrated solar power plant performance. Errors in pointing and tracking mirrors, the canting of individual mirror facets, and the surface slope of the mirror itself can be caused by errors during assembly, transportation, wind loading, gravity, and many other sources. The tools that exist to measure these error sources today largely rely on fringe deflectometry (SOFAST, QDec, others), or photogrammetry with targets attached to the mirror surface. In 2022, NREL presented a new indoor optical measurement system to measure fully assembled heliostats during development and on the assembly line for quality assurance purposes, which has undergone significant development in the last year, including the installation of a new, larger laboratory setup. This system, called ReTNA (Reflected Target Non-intrusive Assessment), uses a printed pattern as a deflectometry target. Using printed pattern features as deflectometry targets instead of fringes allows the software to measure the surface slope in two dimensions, eliminating the need to for changing, projected targets. In the last year, NREL's ReTNA tool has been adapted to use a tall, thin target, that only spans one dimension of the mirror, and a camera moving on an automatic track system. We will present these new developments, including the new setup, target patterns, software methodology for fast, automatic optical analysis, and important lessons learned throughout the process. ReTNA results will be compared to established tools, to establish the uncertainty of this new method. ReTNA leverages recent improvements in computer vision and photogrammetry to remove as much careful calibration from the setup process as possible, making the tool low cost, simple, and portable. While it will not achieve the resolution of a fringe deflectometry system, its advantages make it well suited for CSP evaluation, and allow it to fill a different industry need.

concentrating solar power↗
DOE OSTI2020

A non-intrusive optical (NIO) approach to characterize heliostats in utility-scale power tower plants: Methodology and in-situ validation

No reliable in-situ optical characterization tool is available that can efficiently and accurately measure various optical errors of individual heliostats in a utility-scale power-tower plant. Here, an innovative non-intrusive optical (NIO) approach is proposed to measure mirror surface slope error, mirror facet canting error, and heliostat tracking error based on reflection images using the natural target—the tower—in a heliostat field. The NIO approach adopts various techniques in photogrammetry, reflectometry, and geometrical optics to first determine the camera position and the actual tower position with respect to the heliostat. Then, Snell’s law is applied to find the surface normal at the reflection point or line of a reflection image and derive the surface slope error, mirror facet canting error, and heliostat tracking error accordingly. In addition, an in-situ validation is performed to demonstrate the feasibility of the NIO approach. Analysis with multiple sets of reflection images on one single heliostat of interest demonstrates that the NIO method can achieve a measurement uncertainty of 0.22 mrad for mirror facet slope error (root-mean-square) at the given test conditions. The sensitivity of measurement uncertainty to various parameters will be presented in a separate work. In the future, state-of-the-art unmanned aerial systems (UAS) are planned to perform the efficient image collection with a goal to complete the survey across a utility-scale field of over 10,000 heliostats within one or a few days depending on the number of UASs. The development of the NIO approach is expected to fill the critical gap for successful solar-field operation and maintenance, which is necessary for the global growth of the solar power-tower technology. The NIO approach can also be applied to any relevant industry requiring high-precision mirror surface shape characterization.

14 SOLAR ENERGY↗
DOE OSTI2019

Ex situ metrology and data analysis for optimization of beamline performance of aspherical pre-shaped x-ray mirrors at the advanced light source

Super high quality aspherical x-ray mirrors with a residual slope error of ~100 nrad (root-mean-square) and a height error of ~1-2 nm (peak-to-valley), and even lower, are now available from a number of the most advanced vendors utilizing deterministic polishing techniques. The mirror specification for the fabrication is based on the simulations of the desired performance of the mirror in the beamline optical system and is normally given with the acceptable level of deviation of the mirror figure and finish from the desired ideal shape. For example, in the case of aspherical x-ray mirrors designed for the Advanced Light Source (ALS) QERLIN beamline, the ideal shape is defined with the beamline application (conjugate) parameters and their tolerances. Here, we first introduce an original procedure and dedicated software developed at the ALS X-Ray Optics Laboratory (XROL) for optimization of beamline performance of pre-shaped hyperbolic and elliptical mirrors. The optimization is based on results of ex situ surface slope metrology and consists in minimization of the mirror shape error by determining the conjugate parameters of the best-fit ideal shape within the specified tolerances. We describe novel optical metrology instrumentation, measuring techniques, and analytical methods used at the XROL for acquisition of surface slope data and optimization of the optic’s beamline performance. The high efficacy of the developed experimental methods and data analysis procedures is reflected in results of measurements with and performance optimization of hyperbolic and elliptical cylinder mirrors designed and fabricated for the ALS QERLIN beamline.

47 OTHER INSTRUMENTATION↗
DOE OSTI2023

Supporting data for "Frozen flume experiments indicate rapid permafrost riverbank erosion depends on bank roughness"

This dataset contains supporting files detailing five frozen flume experiments conducted at the Caltech Earth Surface Dynamics Laboratory to investigate rates of ablation-limited permafrost riverbank erosion under controlled conditions. Water flowed past a bank of saturated, frozen sand and ice and gradually eroded the bank by thawing pore ice and immediately entraining sand and washing it downstream. Experiments were scaled for flow hydraulics and heat transfer allowing comparisons between our results and natural permafrost riverbanks. For each experiment, we measured the initial and final sand bank topography using a Keyence laser scanner, water surface slope at 3-min intervals throughout the experiment using a Massa sonar scanner, bank erosion using 10-sec overhead timelapse imagery taken by an overhead camera, water and bank temperature using thermistors frozen into the sand bank and sampling at 2 Hz, and water discharge using an in-line flow meter. We include calibration data for the carriage (engineered by the Saint Anthony Falls Laboratory) used to make sonar and laser topography measurements. We also include calibration data for temperature sensors, water discharge measurements, and images of a regular grid placed in the flume to align overhead camera images with the carriage datum. Grain size analysis for the channel bed (gravel) was produced using a pebble count and bank sand was measured using a Camsizer X2. In addition to the five frozen experiments, we include sonar scans of water surface slope and Keyence scans of bed and bank topography for calibration experiments ran with an immobile gravel bank and bed.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2020

River Plume Liftoff Dynamics and Surface Expressions

The water surface expression of liftoff and its dependence on discharge are examined using numerical simulations with the Regional Ocean Modeling System (ROMS). Liftoff is the process by which buoyant river water separates from the bed and flows over denser saltwater. During low-discharge conditions liftoff occurs in the river and is accompanied by a change in the surface slope. During high-discharge conditions liftoff occurs outside the mouth and generates a ridge on the water surface. The location and height of the ridge can be described by analytical equations in terms of discharge, shelf slope, and river mouth aspect ratio. The offshore distance and height of the ridge are proportional to the river discharge and vary inversely with river mouth aspect ratio. For steep shelf slopes liftoff occurs close to the river mouth and generates a large ridge. The ridge is modified, but not eliminated, by the presence of tides. The water surface slope change at the ridge peak is large enough to be detected by the upcoming Surface Water and Ocean Topography (SWOT) altimeter and can be used to identify the liftoff location during high discharge. However, during low discharge the water surface slope change at the liftoff location is too small to be detected by SWOT. These results indicate that remote measurements of the presence or absence of the ridge may be useful to distinguish between low and high flows, and remote measurements of the ridge location or height could be used to estimate freshwater discharge.

42 ENGINEERING↗
DOE OSTI2018

Ex situ metrology and data processing techniques developed at the ALS for optimization of beamline performance of bendable x-ray mirrors

We discuss experimental, analytical, and numerical methods recently developed at the Advanced Light Source (ALS) X?Ray Optics Laboratory (XROL) for calibration and precision shaping of bendable x-ray mirrors. The methods are based on ex situ measurements with the mirrors using surface slope profilers available at the ALS XROL. The first realization of methods and dedicated software has allowed the optimization of the beamline performance of bendable mirrors by adjustment of the mirror shape to minimize the root-mean-square variation of residual (after subtraction of the ideal desired shape) slope deviations from ideal (specified) surface figure. Here, we further develop the methods that in application to elliptically bent mirrors adapt as a figure of merit the minimum of the rms size of the focused beam. The efficacy of the developed methods is demonstrated with examples of optimal tuning of an elliptically bendable cylindrical mirror designed for the ALS beamline 10.3.2.

Yashchuk, VV↗