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DOE OSTI2022

Structured illumination with thermal imaging (SI-TI): A dynamically reconfigurable metrology for parallelized thermal transport characterization

The recent push for the “materials by design” paradigm requires synergistic integration of scalable computation, synthesis, and characterization. Among these, techniques for efficient measurement of thermal transport can be a bottleneck limiting the experimental database size, especially for diverse materials with a range of roughness, porosity, and anisotropy. Traditional contact thermal measurements have challenges with throughput and the lack of spatially resolvable property mapping, while non-contact pump-probe laser methods generally need mirror smooth sample surfaces and also require serial raster scanning to achieve property mapping. Here, we present structured illumination with thermal imaging (SI-TI), a new thermal characterization tool based on parallelized all-optical heating and thermometry. Experiments on representative dense and porous bulk materials as well as a 3D printed thermoelectric thick film (~50 μm) demonstrate that SI-TI (1) enables paralleled measurement of multiple regions and samples without raster scanning; (2) can dynamically adjust the heating pattern purely in software, to optimize the measurement sensitivity in different directions for anisotropic materials; and (3) can tolerate rough (~3 μm) and scratched sample surfaces. Here, this work highlights a new avenue in adaptivity and throughput for thermal characterization of diverse materials.

42 ENGINEERING↗

DOE OSTI2024

Spinning metasurface stack for spectro-polarimetric thermal imaging

Spectro-polarimetric imaging in the long-wave infrared (LWIR) region plays a crucial role in applications from night vision and machine perception to trace gas sensing and thermography. However, the current generation of spectro-polarimetric LWIR imagers suffers from limitations in size, spectral resolution, and field of view (FOV). While meta-optics-based strategies for spectro-polarimetric imaging have been explored in the visible spectrum, their potential for thermal imaging remains largely unexplored. In this work, we introduce an approach for spectro-polarimetric decomposition by combining large-area stacked meta-optical devices with advanced computational imaging algorithms. The co-design of a stack of spinning dispersive metasurfaces along with compressive sensing and dictionary learning algorithms allows simultaneous spectral and polarimetric resolution without the need for bulky filter wheels or interferometers. Our spinning-metasurface-based spectro-polarimetric stack is compact (<10×10×10cm) and robust, and it offers a wide field of view (20.5°). We show that the spectral resolving power of our system substantially enhances performance in machine learning tasks such as material classification, a challenge for conventional panchromatic thermal cameras. Our approach represents a significant advance in the field of thermal imaging for a wide range of applications including heat-assisted detection and ranging (HADAR).

Optics↗

DOE OSTI2024

ThermoPore: Predicting part porosity based on thermal images using deep learning

Part qualification is often a critical and labor-intensive process in additive manufacturing, particularly in the detection of defects such as porosity, which stands to benefit significantly from advancements in machine learning. We present a deep learning approach for quantifying and localizing ex-situ porosity within Laser Powder Bed Fusion fabricated samples utilizing in-situ thermal image monitoring data. Our goal is to build the real time porosity map of parts based on thermal images acquired during the build. The quantification task builds upon the established Convolutional Neural Network model architecture to predict pore count and the localization task leverages the spatial and temporal attention mechanisms of the novel Video Vision Transformer model to indicate areas of expected porosity. Our model for porosity quantification achieved a R 2 score of 0.57 and our model for porosity localization produced an average Intersection over Union (IoU) score of 0.32 and a maximum of 1.0. This work is setting the foundations of part porosity “Digital Twins” based on additive manufacturing monitoring data and can be applied downstream to reduce time-intensive post-inspection and testing activities during part qualification and certification. In addition, we seek to accelerate the acquisition of crucial insights normally only available through ex-situ part evaluation by means of machine learning analysis of in-situ process monitoring data.

Deep learning↗

DOE OSTI2021

Phenotyping stomatal closure by thermal imaging for GWAS and TWAS of water use efficiency-related genes

Abstract Stomata allow CO2 uptake by leaves for photosynthetic assimilation at the cost of water vapor loss to the atmosphere. The opening and closing of stomata in response to fluctuations in light intensity regulate CO2 and water fluxes and are essential for maintaining water-use efficiency (WUE). However, a little is known about the genetic basis for natural variation in stomatal movement, especially in C4 crops. This is partly because the stomatal response to a change in light intensity is difficult to measure at the scale required for association studies. Here, we used high-throughput thermal imaging to bypass the phenotyping bottleneck and assess 10 traits describing stomatal conductance (gs) before, during and after a stepwise decrease in light intensity for a diversity panel of 659 sorghum (Sorghum bicolor) accessions. Results from thermal imaging significantly correlated with photosynthetic gas exchange measurements. gs traits varied substantially across the population and were moderately heritable (h2 up to 0.72). An integrated genome-wide and transcriptome-wide association study identified candidate genes putatively driving variation in stomatal conductance traits. Of the 239 unique candidate genes identified with the greatest confidence, 77 were putative orthologs of Arabidopsis (Arabidopsis thaliana) genes related to functions implicated in WUE, including stomatal opening/closing (24 genes), stomatal/epidermal cell development (35 genes), leaf/vasculature development (12 genes), or chlorophyll metabolism/photosynthesis (8 genes). These findings demonstrate an approach to finding genotype-to-phenotype relationships for a challenging trait as well as candidate genes for further investigation of the genetic basis of WUE in a model C4 grass for bioenergy, food, and forage production.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2024

Canopy reflectance spectroscopy, thermal images and digital photographs, San Lorenzo, Panama, 2020

This data package comprises reflectance spectra, thermal and visible images of top of canopy tree crowns at the San Lorenzo Protected Area, Panama. Data were collected using the Smithsonian Tropical Research Institute (STRI) canopy access crane, from positions approximately 4 m above the target tree canopy. Canopy reflectance spectra were collected using an HR-1024i full range spectroradiometer (350–2500 nm, SVC, Poughkeepsie, NY, USA) with a 14-degree lens. Canopy thermal images were captured using an 8640-S series USB Calibrated Thermal Camera (ICI International, Beaumont, TX, USA). Visible images were collected using an AW130 waterproof/shockproof camera (Nikon, Tokyo, Japan). Data were collected on three days, on 16 canopies from 10 tree species. On both January 30, 2020, and February 27, 2020, we collected spectra at three time points, in the morning, midday, and afternoon. On February 18, 2020, we collected data around midday only. Due to technical issues, digital photography was collected on 30 January only. This dataset includes unprocessed data only, including spectral data (.sig or .sed), thermal images (.i16), and photographs (.raw), a detailed method description (.pdf), species information (.csv) and ESS-DIVE file-level metadata (FLMD.csv).

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2021

Performance of Compact Pulsed Thermal Imaging System for In-Service Applications. Pulsed thermal tomography nondestructive examination of additively manufactured reactor materials and components

Additive manufacturing (AM) is an emerging method for cost-efficient fabrication of complex topology nuclear reactor parts from high-strength corrosion resistance alloys, such as stainless steel and Inconel. AM of metallic structures for nuclear energy applications is currently based on laser powder bed fusion (LPBF) process, which has the capability of melting metallic powder and net shaping the structures with relatively high precision. Some of the challenges with using LPBF method for nuclear manufacturing include the possibility of introducing pores into metallic structures. Integrity of AM structures needs to be evaluated nondestructively because material flaws could lead to premature failures due to creep in high temperature nuclear reactor environment. Currently, there exist limited capabilities to evaluate actual AM structures nondestructively. Pulsed Thermography (PT) imaging provides a capability for non-destructive evaluation (NDE) of sub-surface defects in arbitrary size structures. The PT method is based on recording material surface temperature transients with infrared (IR) camera following thermal pulse delivered on material surface with flash light. The PT method has advantages for NDE of actual AM structures because the method involves one-sided non-contact measurements and fast processing of large sample areas captured in one image. The data cube of PT measurements consists of surface temperature taken at sequential time intervals T(x,y,t). Material defects can be detected either by analyzing the thermograms T(x,y,t) data cube, or by using thermal tomography (TT) algorithm to obtain 3D spatial reconstruction of thermal effusivity e(x,y,z). To reduce the cost and enable in-service NDE in spatially constrained environment, it is highly desirable to develop PT with compact and inexpensive IR camera. Following initial qualification of an AM component for deployment in a nuclear reactor, a compact PT system can also be used for in-service nondestructive evaluation (NDE) applications. However, data cube obtained with PT based on compact IR camera suffers from strong thermal noises and loss of features due to relatively low sampling rate. In this report we describe two unsupervised machine learning (ML) algorithms for enhancement of PT images obtained with compact IR camera. In one approach, we introduce Sparse Coding Discrete Cosine Transform (SC/DCT) algorithm to remove additive white Gaussian noise (AWGN) from spatial thermal effusivity reconstructions. In another approach we introduce a Spatial Temporal Denoised Thermal Source Separation (STDTSS) ML algorithm to process thermograms. The STDTSS algorithm consists of spatial and temporal denoising using Gaussian and Savitzky–Golay filtering, followed by the matrix decomposition using Principal Component Analysis (PCA), and Independent Component Analysis (ICA) to automatically detect flaws. In the work described in this report, we constructed a compact PT system using a relatively small and low-cost FLIR A65 camera, consisting on uncooled microbolometer detector. Performance of SC/DCT algorithm was demonstrated on enhancing TT images of Inconel 718 AM plate. Performance of the STDTSS methods was investigated using thermography data obtained from imaging stainless steel 316L specimens produced with LPBF method with imprinted calibrated porosity defects.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2025

Solution-Processed Temperature-Adaptive Radiative Paint as a Thermal Imaging Sensitizer

Thermography detects mid-infrared radiation from surfaces based on the Stefan-Boltzmann law, mapping surface temperatures and potentially revealing subsurface thermal activity. Recent developments offer an alternative strategy to traditional camera-based improvements: a thermal imaging sensitizer (TIS) coating whose emissivity increases sharply with local temperature, amplifying small thermal variations into high-contrast signals. Existing TIS structures are nanofabricated solid membranes and face significant challenges in fabrication complexity. Here, in this study, we present a solution-processed, liquid form of TIS, termed temperature-adaptive radiative paint (TARP), to address these limitations. TARP offers drastically reduced fabrication costs, scalability to large areas, applicability to curved surfaces, and an extended operating temperature range, while maintaining the function of temperature amplification. Application of TARP enhances small temperature contrast by more than 3 times, substantially improving ambient thermography and enabling broader applications such as detection of structural defects and hot spots in electronic components.

paint↗

DOE OSTI2026

Stereo-vision thermal imaging system for tracking flying animals in wind farm areas (CRADA #763) Abstract

CRADA 763: abstract ThermalTracker-3D (TT3D) is a stereo vision thermal imaging system that provides 3D flight information on detected birds, bats, and other flying targets. The system was initially developed for use in the siting and monitoring of offshore wind projects to establish pre-construction and operation collision risk data but can be applied to terrestrial wind energy projects as well as national security monitoring. This technology will reduce monitoring cost, decrease processing time, and provide more accurate data for wind energy developers/operators and regulatory agencies. While the current technology is at a high level of readiness, Technology Readiness Level (TRL) 7, there remain several barriers to commercialization, particularly around ease-of-use, that result in a low Adoption Readiness Level (ARL). The proposed work will advance commercialization readiness by streamlining calibration methods for built systems. This work will:1. 1. develop a software package for factory and dynamic calibration processes 2. test that package with existing prototype TT3D systems, and 3. conduct outreach with industry end-users.

ThermalTracker↗

DOE OSTI2025

In situ Visible Light and Thermal Imaging Data from a Laser Powder Bed Fusion Additive Manufacturing Process Co-Registered to X-ray Computed Tomography and Fatigue Data

This dataset is comprised of in situ sensing data collected during a laser-based powder bed fusion additive manufacturing process, as well as rasterized scan path information, post-build X-ray computed tomography (XCT), and fatigue test results. A total of 64 cylinders, approximately 15 mm in diameter and 102 mm tall, were printed out of stainless steel 316H on a Colibrium Additive Concept Laser M2 Series 5 machine. Parameters known to produce dense material were used to construct 56 of these cylinders, while the remaining 8 cylinders were printed with relatively high energy density parameters prone to producing keyhole pores. In addition, two spatter generation blocks were constructed upstream of the 64 cylinders such that ejecta produced during the melting of the spatter generators were stochastically seeded onto the 64 cylinders. Based on previous experiments, these spatter particles were theorized to produce stochastic lack-of-fusion pores. During the construction of the build, high-resolution images of reflected light in the visible spectrum were captured both before and after recoating for each print layer. Additionally, temporally integrated thermal imaging in the near infrared spectrum produced integrated sum and max images on a layerwise basis. The multimodal in situ data has been co-registered to the build plate coordinate system, allowing for identification of process anomalies (e.g., spatter particles) apparent in the two sensors. Following construction of the build, the cylinders were subjected to XCT to identify internal flaws, and the resulting data have also been registered to the build plate coordinate system. Finally, 60 of the 64 cylinders were machined into fatigue coupons conforming to ASTM E466 and subsequently subjected to either high- or -low-cycle fatigue testing. The results of the fatigue tests have also been included in the dataset, and the XCT data corresponded to the approximate location of the gauge sections of the machine fatigue specimen geometry.

42 ENGINEERING↗

DOE OSTI2024

High-temperature thermal imaging to inform the arc-melt synthesis of nuclear materials

The advancement of nuclear energy technology necessitates the development of novel materials and synthesis methods to produce materials which enable new fuel cycles. Alongside the maturation of R&D scale technologies to produce these materials, there is an ongoing effort to develop in situ monitoring capabilities to reduce the time to the discovery and development of these fuels. Monitoring data can be leveraged in artificial intelligence platforms to detect phenomena which lead to varied macro- and microstructural features which impact the application and performance of samples synthesized. The present study presents early-stage findings of the implementation of high-temperature, high-frame-rate infrared thermal imaging to monitor the arc-melt synthesis of novel fuels and compounds relevant to advanced nuclear reactors. The study illustrates both the challenges and opportunities of this methodology, highlighting the importance of internal standards while determining emissivity and transmission values as well as visualizing volatilization during melt synthesis.

Stone, Jordan↗

DOE OSTI2022

Predicting defects in laser powder bed fusion using in-situ thermal imaging data and machine learning

Variation in the local thermal history during the Laser Powder Bed Fusion (LPBF) process in Additive Manufacturing (AM) can cause micropore defects, which add to the uncertainty of the mechanical properties (e.g., fatigue life, tensile strength) of the built materials. In-situ sensing has been proposed for monitoring the AM process to minimize defects, but successful minimization requires establishing a quantitative relationship between the sensing data and the porosity, which is particularly challenging with a large number of variables (e.g., laser speed, power, scan path, powder property). Physics-based modeling can simulate such an in-situ sensing-porosity relationship, but it is computationally costly. In this work, we develop Machine Learning (ML) models that can use in-situ thermographic data to predict the micropore of LPBF stainless steel materials. This work considers two identified key features from the thermal histories: the time above the apparent melting threshold ($\tau$) and the maximum radiance ( T max ). These features are computed, stored for each voxel in the built material, and then used as inputs. The binary state of each voxel, either defective or normal, is the output. Different ML models are trained and tested for the binary classification task. In addition to using the thermal features of each voxel to predict its own state, the thermal features of neighboring voxels are also included as inputs. This is shown to improve the prediction accuracy, which is consistent with thermal transport physics around each voxel contributing to its final state. Among the models trained, the F1 scores on test sets reach above 0.96 for Random Forests. Feature importance analysis based on the ML models shows that T max is more important to the voxel state than $\tau$ . The analysis also finds that the thermal history of the voxels above the present voxel is more influential than those beneath it. Our study significantly extends the capability of using in-situ thermographic data to predict porosity in LPBF materials. Finally, since ML models are fast, they may play integral roles in the optimization and control of such AM technologies.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Multispectral and Thermal Imager Onboard Aerial Platforms Instrument Handbook

The MicaSense Altum imager is an off-the-shelf, synchronized multispectral and thermal camera, combined with a Global Positioning System (GPS) unit and downwelling light sensor (DLS). The Altum takes images of the land surface within its field of view (FOV) across five visible bands and one longwave infrared thermal band. The sensor records the radiance and converts it to digital numbers. Imagery is radiometrically corrected, taking into account the sensor calibration, lens distortions, vignette effects, sun angle, and atmospheric effects (scattering and absorption). The photogrammetry software Agisoft PhotoScan v 1.4 is used to align and stitch the images into a larger composite image using the technique of structure from motion image capture to construct a dense cloud and 3D model of the surface, which is used to produce a digital elevation model of the terrain surveyed and orthomosaic imagery. Land surface leaf area index, albedo, and surface skin temperature are provided for the user. The user can perform raster calculations on the imagery to produce various other vegetative indices, which are used to indicate plant health and land surface characteristics, including Normalized Difference Vegetation Index (NDVI), Green Normalized Difference Vegetation Index (GNDVI), Normalized Difference Water Index (NDWI), surface temperature, and Enhanced_vegetation_index (EVI). This code is provided with the readme file for each data set. The images have a resolution of 20-60 cm/pixel, which are subsampled to 100 cm/pixel.

47 OTHER INSTRUMENTATION↗

DOE OSTI2021

Performance Validation of Pulsed Thermal Imaging System for In-Service Applications

42 ENGINEERING↗

DOE OSTI2023

Luminescence and Thermal Imaging Applied to Half-Cut-Cell and Emitter-Wrap-Through-Cell Modules

Imaging techniques provide spatial details and visualization of module defects and degradation mechanisms that affect energy conversion efficiency and performance. We apply photoluminescence, electroluminescence, and dark lock-in thermography imaging techniques to evaluate new modules in their initial state and after applying stresses of damp heat, light-induced-degradation regeneration parameters, thermal cycling, and humidity-freeze cycles. One module uses emitter-wrap-through cells with back contacts connected to a metal-foil backplane, and the other is composed of half-cut cells. Imaging shows examples on non-uniform degradation and damage such as cells that degrade and recover under the applied conditions, cells with cracks and handling damage, and cells with increasing series resistance.

degradation↗

DOE OSTI2021

Local prediction of Laser Powder Bed Fusion porosity by short-wave infrared imaging thermal feature porosity probability maps

We report that local thermal history can significantly vary in parts during metal Additive Manufacturing (AM), leading to local defects. However, the sequential layer-by-layer nature of AM facilitates in-situ part voxelmetric observations that can be used to detect and correct these defects for part qualification and quality control. The challenge is to relate this local radiometric data with local defect information to estimate process error likelihood in future builds. This paper uses a Short-Wave Infrared (SWIR) camera to record the temperature history for parts manufactured with Laser Powder Bed Fusion (LPBF) processes. The porosity from a cylindrical specimen is measured by ex-situ micro-computed tomography (μCT). Specimen data from the SWIR camera, combined with the μCT data, are used to generate thermal feature-based porosity probability maps. The porosity predictions made by various SWIR thermal feature-porosity probability maps of a specimen with a complex geometry are scored against the true porosity obtained via μCT. The receiver operating characteristic curves constructed from the predictions for the complex sample demonstrate the porosity probability mapping methodology’s potential for in-situ based porosity detection.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Thermal images collected during large-scale 3D printing with Ingersoll MasterPrint

This data set contains images produced to test the performance of anomaly and fault detection methods in the context of additive manufacturing. Two print jobs were executed using the Ingersoll MasterPrint with the Model 30 Strangpresse extruder. The material used was Techmer compounded polylactic acid (PLA) with wood flour as a filler (80/20 PLA/WF by weight). The first print job consists of the 3D printing of a hexagonal cylinder with a two-bead wall. This print was sliced at a gantry velocity of 3000 millimeter per minute, and an extruder screw speed of 68.14 rotations per minute. This are considered the normal operating conditions. A second hexagonal cylinder was printed using a reduced extruder screw speed, 15% lower than under normal operating conditions. The images were collected with a Teledyne FLIR Lepton 3.5 infra-red camera, a small form factor radiometric long-wave infrared camera with a spectral range of 8 µm to 14 µm. Sensor resolution was 160x120 pixels, with a pixel size of 12 µm, a temperature range of -10 - 450°C, and an accuracy of +/- 10°C in its low gain configuration. Images in this data set were collected with cameras oriented at the printer nozzle. The nozzle camera setup consisted of two cameras located 12.5cm from the nozzle center. These were mounted directly to the print head, so that the camera positions relative to the print direction would remain constant as it rotated around its C-axis to follow the print path. One camera was placed ahead of the nozzle to capture the previous layer immediately before being covered by the new layer of material, while the second camera was placed behind the nozzle and captured the freshly extruded bead. Images are collecting during each phase of the print: (a) idle (i.e., no material deposited), (b) extrusion (i.e., to prime the extruder), and (c) printing (deposition of material to manufacture the hexagonal cylinder).

36 MATERIALS SCIENCE↗

DOE OSTI2026

Thermal images collected during 3D printing with Cincinnati BAAM

This data set contains images produced to test the performance of anomaly and fault detection methods in the context of additive manufacturing. A total of 10 print jobs were executed using a Cincinnati BAAM (model 606) with a Cincinnati medium compression screw. The material used was compounded polylactic acid (PLA) with wood flour as a filler produced by Jabil (80% NatureWorks Ingeo 6060D amorphous PLA, % 100 mesh pine flour from American Wood Fiber). Print sheets were 1/4in polycarbonate.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Two-color high speed thermal imaging system for laser-based additive manufacturing process monitoring

Monitoring melt pool temperature in laser powder bed fusion by providing a build laser that produces a laser beam that is directed onto the melt pool and produces an incandescence that emanates from the melt pool, receiving the incandescence and producing a first image having a first spectral band and a second image having a second spectral band, and determining the ratio of said first image having a first spectral band and said second image having a second spectral band to monitor the melt pool temperature.

Calta, Nicholas P.↗