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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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18 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Wireless Interrogation of High Temperature Surface Acoustic Wave Dynamic Strain Sensor

Dynamic strain sensing is necessary for high-temperature harsh-environment applications, including powerplants, oil wells, aerospace, and metal manufacturing. Monitoring dynamic strain is important for structural health monitoring and condition-based maintenance in order to guarantee safety, increase process efficiency, and reduce operation and maintenance costs. Sensing in high-temperature (HT), harsh-environments (HE) comes with challenges including mounting and packaging, sensor stability, and data acquisition and processing. Wireless sensor operation at HT is desirable because it reduces the complexity of the sensor connection, increases reliability, and reduces costs. Surface acoustic wave resonators (SAWRs) are compact, can operate wirelessly and battery-free, and have been shown to operate above 1000°C, making them a potential option for HT HE dynamic strain sensing. This paper presents wirelessly interrogated SAWR dynamic strain sensors operating around 288.8MHz at room temperature and tested up to 400°C. The SAWRs were calibrated with a high-temperature wired commercial strain gauge. The sensors were mounted onto a tapered-type Inconel constant stress beam and the assembly was tested inside a box furnace. The SAWR sensitivity to dynamic strain excitation at 25°C, 100°C, and 400°C was .439 μV/με, 0.363μV/με, and .136 μV/με, respectively. Furthermore, the experimental outcomes verified that inductive coupled wirelessly interrogated SAWRs can be successfully used for dynamic strain sensing up to 400°C.

47 OTHER INSTRUMENTATION↗
DOE OSTI2023

Reflective Fiber Temperature Probe Based on Localized Surface Plasmon Resonance towards Low-Cost and Wireless Interrogation

Reflection fiber temperature sensors functionalized with plasmonic nanocomposite material using intensity-based modulation are demonstrated for the first time. Characteristic temperature optical response of the reflective fiber sensor is experimentally tested using Au-incorporated nanocomposite thin films deposited on the fiber tip, and theoretically validated using a thin-film-optic-based optical waveguide model. By optimizing the Au concentration in a dielectric matrix, Au nanoparticles (NP) exhibit a localized surface plasmon resonance (LSPR) absorption band in a visible wavelength that shows a temperature sensitivity ~0.025%/°C as a result of electron–electron and electron–phonon scattering of Au NP and the surrounding matrix. Detailed optical material properties of the on-fiber sensor film are characterized using scanning electron microscopy (SEM) and focused-ion beam (FIB)-assisted transmission electron microscopy (TEM). Airy’s expression of transmission and reflection using complex optical constants of layered media is used to model the reflective optical waveguide. A low-cost wireless interrogator based on a photodiode transimpedance-amplifier (TIA) circuit with a low-pass filter is designed to integrate with the sensor. The converted analog voltage is wirelessly transmitted via 2.4 GHz Serial Peripheral Interface (SPI) protocols. Feasibility is demonstrated for portable, remotely interrogated next-generation fiber optic temperature sensors with future capability for monitoring additional parameters of interest.

47 OTHER INSTRUMENTATION↗
DOE OSTI2023

Individually identifiable surface acoustic wave sensors, tags and systems

A surface-launched acoustic wave sensor tag system for remotely sensing and/or providing identification information using sets of surface acoustic wave (SAW) sensor tag devices is characterized by acoustic wave device embodiments that include coding and other diversity techniques to produce groups of sensors that interact minimally, reducing or alleviating code collision problems typical of prior art coded SAW sensors and tags, and specific device embodiments of said coded SAW sensor tags and systems. These sensor/tag devices operate in a system which consists of one or more uniquely identifiable sensor/tag devices and a wireless interrogator. The sensor device incorporates an antenna for receiving incident RF energy and re-radiating the tag identification information and the sensor measured parameter(s). Since there is no power source in or connected to the sensor, it is a passive sensor. The device is wirelessly interrogated by the interrogator.

Hines, Jacqueline H.↗
DOE OSTI2025

Wireless Patch Antenna Characterization for Live Health Monitoring Using Machine Learning

Temperature monitoring in extreme environments, such as coal-fired power plants, was addressed by designing and testing wireless patch antennas for use in machine learning-aided temperature estimation. The sensors were designed to monitor the temperature and health of boiler systems. Wireless interrogation of the sensor was performed using a Vector Network Analyzer (VNA) and a pair of interrogation antennas to capture resonance behavior under varying thermal and spatial conditions with sensitivities ranging from 0.052 to 0.20 $\frac{𝑀𝐻𝑧}{°C}$. Sensor calibration was conducted using a Long Short-Term Memory (LSTM) model, which leveraged temporal patterns to account for hysteresis effects. The calibration method demonstrated improved performance when combined with an LSTM model, achieving up to a 76% improvement in temperature estimation error when compared with Linear Regression (LR). The experiments highlighted an innovative solution for patch antenna-based non-contact temperature measurement, which addresses limitations with conventional methods such as RFID-based systems, infrared, and thermocouples.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2020

Development and Test of High Temperature Surface Acoustic Wave Gas Sensors

The demand for sensors in hostile environments, such as power plant environments, aerospace environments, oil and gas extraction, and high-temperature metallurgy environments, has risen over the past decades in a continuous attempt to increase process control, improve energy and process efficiency in production, reduce operational and maintenance costs, increase safety, and perform condition-based maintenance in equipment and structures operating in high-temperature harsh-environment conditions. The increased reliability, improved performance, and development of new sensors and networks with a multitude of components, especially wireless networks, are the target for operation in harsh environments. Gas sensors, in particular H2 sensors, operating above 200 C are required in the instrumentation, process control and general safety of a number of industries including coal, natural gas, and nuclear power generation facilities, the aerospace and automotive industries, metallurgical production and defense-related applications. The surface acoustic wave (SAW) platform is a particularly promising option for high-temperature, harsh-environment gas sensing applications since the platform exhibits advantages, such as battery-free and wireless operation, small size, possibility for scale production using well-developed technologies from the semiconductor industry, and low cost of installation and operation. In this work, one-port SAW resonators (SAWRs) operating along five different orientations on a commercially available langasite (LGS) wafer employing Pt-Al2O3 electrodes and reflectors were designed, fabricated, and used as high-temperature H2 sensors. Two of the selected orientations were predicted and confirmed to have temperature-compensated operation above 150 C. A gas sensor test setup was developed, capable of gas cycling between N2, O2 and N2/H2 mixtures under extended high-temperature periods (up to 650 C for over 20 hours). Thin film Pt-Al2O3 was used as the electrode material for the transducers and reflectors capable of high-temperature operation, and also as H2 sensing film. In addition, yttria-stabilized zirconia (YSZ) thin films with Pt decoration were tested as sensing films aimed to enhance the SAWR sensor response to H2. The SAW devices were monitored in excess of 1700 hours in real-time during gas cycling sequences up to 600 C, leading to the following findings: i) the Pt-Al2O3 electrodes performed better for H2 sensing than the Pt-decorated YSZ sensing film, showing as much as 50% higher frequency variation response in the 200 C to 400 C range; ii) different crystallographic orientations operating on the same LGS wafer experienced different responses to H2 exposures up to 500 C; iii) the surface oxidation state of the SAWR sensors was shown to have an important impact on subsequent H2 exposure responses. In addition, a sensor system employing two LGS SAWRs, aligned along two different orientations, has been developed to simultaneously determine H2 presence and temperature. Finally, wireless interrogation of a SAWR sensor was successful within the gas cycling test fixture, and successful wireless H2 detection was achieved above 400 C.

Ayes Moncada, Armando↗
DOE OSTI2020

Static Strain Modelling, Calibration, and Measurements for High-Temperature Wireless SAW Resonator Operation

Static strain measurements are relevant for Integrated System Health Monitoring of civil structures, aircrafts, power plants and advanced manufacturing equipment, with implications for safety, process efficiency, and maintenance costs. Wireless strain sensing is highly desirable where the presence of wires poses significant safety concerns, increases maintenance, and thus overall costs, or where they are not feasible, such as in applications which contain moving parts. This paper presents wireless interrogation of surface acoustic wave resonators (SAWRs) fabricated on langasite (LGS) along Euler angles (0°, 138.5°, 32.9°) and aimed at the detection of static strain at hightemperature (HT, above 100°C). Both commercial HT strain gauges and finite element analysis (FEA Abaqus software) were used and compared for SAWR strain calibration from room temperature (RT) to HT. In addition, this work investigated a compromise between high temperature operation vs. sensitivity based on the thickness of ceramic adhesive used. For instance, a reduction in the adhesive thickness from about 150 μm to 135 μm, resulted in a 39% increase in sensitivity at RT. It was also observed that the sensitivity dropped up to 34% from RT to 200°C. Furthermore, wireless operation, calibration, and increase in sensitivity constitute important advances in the use of LGS SAW devices to monitor static stress in high-temperature harsh environments.

42 ENGINEERING↗
DOE OSTI2020

Integrated Harsh Environment Gas / Temperature Wireless Microwave Acoustic Sensor System for Fossil Energy Applications

There is a significant need for sensors capable of detecting gases, such as H 2 , O 2 , NO x , SO x within harsh environments encountered in power plants, industrial manufacturing, oil and gas exploration, and aerospace applications. This project successfully demonstrated the use of wireless microwave acoustic sensor technology for the detection of gases (H 2 or O 2 ) from ambient temperatures up to 650°C. The work focused on langasite (LGS) based surface acoustic wave resonator (SAWR) sensors as the harsh-environment sensor platform and explored multiple combinations of high-temperature thin films and device structures which were used to increase the sensor platform stability and detection capability at temperatures in the operational range of 150°C to 700°C. Specific material configurations that were investigated include: yttria-stabilized-zirconia (YSZ) decorated with Pt nanoparticles, atomic layer deposited (ALD) Al 2 O 3 , palladium, and Pt/Al 2 O 3 co-deposited electrode alloys. Through the deposition of YSZ at temperatures as high as 850°C and the use of graded alloy concentrations of Pt in the fabrication of the Pt/Al 2 O 3 electrode structures, film stress problems were mitigated, and sensor operation and stability achieved. To test and evaluate SAWR sensor performance for the detection of H 2 and O 2 under the influence of temperature variations, a comprehensive gas sensor control system and test apparatus was created to operate within a laboratory box furnace-controlled environment. In addition to the advancement in thin film materials through the deposition and fabrication techniques mentioned above, the work characterized the performance of sensors containing these films in the presence of oxidizing and reducing gases between 25°C and 700°C. In particular, the work revealed that the exposure of the SAWR sensor surfaces to oxidizing environments significantly improve the sensor response to H 2 , whereas the exposure of the sensor to reducing environments at high temperatures (≈ 500°C) renders the sensor irresponsive to H 2 , requiring sensor surface treatment at high temperatures (above 500°C) to recover the responsiveness to H 2 . The SAWR sensors have been also tested for wireless operation and array operation using multiple orientations to resolve the detection of gases under temperature variations. The work developed at the University of Maine was aided by a collaboration with the NETL Research and Innovation Center, Pittsburgh, PA, where thin film materials and device structures fabricated at UMaine were tested and characterized using NETL gas reactors and surface analysis techniques. SAWR sensors fabricated at UMaine were exposed multiple times to temperatures up to 700°C and H 2 concentrations up to 100% in the NETL facilities to measure the sensor performance. Environetix Technologies Corporation, a UMaine harsh-environment sensor spin-off company, also provided support and assistance in sensor system testing and implementation. The sensor small size and configuration allows flexible sensor placement and embedding of multiple sensor arrays into a variety of components within power systems and other aerospace or industrial settings that need to be interrogated wirelessly. The SAW platform is an attractive option for high-temperature harsh-environment gas sensing applications due to its inherent features, namely small size, capability of battery-free and wireless operation, and cost effective scale production using well-established production techniques from the semiconductor industry. The research findings achieved in this work, particularly advances regarding the fabrication and performance of the SAWR gas sensor platform, can be adapted and transferred to industrial power plants and other harsh environments.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2022

Temperature and Dynamic Strain Measurements Using a Single SAWR Sensor

Dynamic strain sensing is relevant in numerous applications involving structural health monitoring, condition-based maintenance, operation efficiency preservation, and work environment safety. These sensors are particularly critical for high-temperature (HT) harsh-environment (HE) industries such as aerospace, automotive, power plants, and advanced manufacturing. In HT/HE, sensor implementation and measurement present challenges such as maintaining sensor stability, accounting for temperature cross-sensitivity, providing HT attachment, and packaging of the sensors and system. Surface acoustic wave resonator (SAWR) sensors can address these needs and offer additional benefits such as compact size and wireless interrogation capability. The SAWR sensitivity to dynamic strain is temperature dependent, making it necessary to measure the sensor temperature in order to use the correct dynamic strain calibration curve. In this work, a method for determining the temperature, dynamic strain magnitude, and dynamic strain spectral components using a single SAWR sensor is presented. Here, the established technique for determining operational temperature and dynamic strain magnitude/spectral components using only one SAWR simplifies the sensor measurement system, thus being very attractive for HT /HE applications.

47 OTHER INSTRUMENTATION↗
DOE OSTI2024

Miniaturized Magnetoelastic Sensor System

This article describes the design, assembly, and implementation of a hand-held, magnetic-field-based sensor system that can be adapted for a variety of sensing applications. The miniaturized system is based on Chemical Identification by Magneto-Elastic Sensing (ChIMES) technology, which uses three concentric solenoid coils to wirelessly interrogate a sensor body comprised of a response material coupled to a magnetoelastic wire. The response material expands when it encounters a target, imposing mechanical stress on the wire and altering its magnetic permeability. The sensor bodies are passive, requiring no external power source, and they are small, measuring about 15 mm in length and 3.0 mm in diameter. Up to four sensor bodies can be configured as an evenly-spaced linear array. The sensor system operates by applying a low-frequency, current-stabilized, filtered triangle wave to a uniform-density excitation coil to switch the magnetic domains within the wire. Further, the responses from the sensors are picked up by a detection coil as stress-induced changes in the Faraday voltage, and the strong magnetic field induced by the excitation coil in the detection coil is nullified by a cancellation coil reverse-wound in series with the detection coil. The responses of the sensors in an array are separated in time by a linear gradient dc biasing coil. The sensors can be interrogated through metallic and nonmetallic barriers. The signals from the detection coil and the excitation coil are digitized by a pair of bipolar analog-to-digital converters (ADCs). A Raspberry Pi single-board computer (SBC) and associated software perform data acquisition and control all aspects of the sensor system hardware. The program allows the user to select the number of sensors in the array, the type of signal that is being collected, and the number of samples to take. The program also allows for signal processing of the sensor data, such as baseline correction. The program can differentiate sensor peaks from each other and calculate the magnitude of each sensor response with less than 1% error. The data are then displayed along with a graph of the signal.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2023

Surface acoustic wave sensor interrogation using Goubau waves

Electromagnetic waves on single conductors (Goubau waves) are studied for the interrogation of wireless sensors. A demonstration of interrogation of a surface acoustic wave (SAW) sensor is presented, followed by the results of simulation of wave launchers on conductors of varying radius.

Greve, David↗
DOE OSTI2021

Microwave diagnostics and passive sensors for pipeline, well-bore, and boiler-tube monitoring

Materials, methods of making, and methods of using an integrated wireless detector for real time interrogating metallic tubular structures comprising: an RF patch antenna; a passive surface acoustic wave (SAW) sensor; and data analytic methodologies. An embodiment relates to interrogating a metallic structure having a uniform cross section using an antenna which launches electromagnetic radiation. A sensor may be located within the structure is configured to re-emit electromagnetic radiation modified depending on parameters for which the sensor has been functionalized. An antenna may receive radiation as modified by the sensor, or may receive the transmitted or backscattered radiation directly, without use of a sensor. The antenna then communicates wirelessly with an interrogator providing data which may be used to understand the operational status of the structure in real-time.

Ohodnicki, Paul R.↗
DOE OSTI2024

Near-Field Passive Wireless Sensor for High-Temperature Metal Corrosion Monitoring

This work focuses on the fabrication and evaluation of a passive wireless sensor for the monitoring of the temperature and corrosion of a metal material at high temperatures. An inductor–capacitor (LC) resonator sensor was fabricated through the screen printing of Ag-based inks on dense polycrystalline Al 2 O 3 substrates. The LC design was modeled using the ANSYS HFSS modeling package, with the LC passive wireless sensors operating at frequencies from 70 to 100 MHz. The wireless response of the LC was interrogated and received by a radio frequency signal generator and spectrum analyzer at temperatures from 50 to 800 °C in real time. The corrosion kinetics of the Cu 110 was characterized through thermogravimetric (TGA) analysis and microscopy images, and the oxide thickness growth was then correlated to the wireless sensor signal under isothermal conditions at 800 °C. The results showed that the wireless signal was consistent with the corrosion kinetics and temperature, indicating that these two characteristics can be further deconvoluted in the future. In addition, the sensor also showed a magnitude- and frequency-dependent response to crack/spallation events in the oxide corrosion layer, permitting the in situ wireless identification of these catastrophic events on the metal surface at high temperatures.

36 MATERIALS SCIENCE↗
DOE OSTI2023

WIRE-21 Experiment Irradiation Conditions and In-Situ Data Collection

This report summarizes the in situ data collected during three cycles of irradiation (~75 days) of the Wireless Instrumented Removable Beryllium Experiment 2021 (WIRE-21) in the removable beryllium (RB) positions of the High Flux Isotope Reactor (HFIR). The experiment was designed primarily to evaluate the effects of high neutron flux and fluence on the performance of wireless temperature and pressure sensors being developed by Westinghouse Electric Company (WEC). WEC’s sensors could provide critical data regarding the evolution of centerline temperatures and pressurization due to fission gas release during fuel operation in light-water reactors (LWRs) or various advanced reactor applications. In addition to WEC’s wireless sensors, many other sensors were interrogated, including thermocouples, self-powered neutron detectors (SPNDs), distributed fiber optic temperature sensors, and passive neutron flux wires and silicon carbide thermometry.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2025

Passive Wireless Sensors for Realtime Temperature and Corrosion Monitoring of Coal Boiler Components Under Flexible Operation (Final Technical Report)

Researchers at West Virginia University (WVU) propose to demonstrate inexpensive wireless, high-temperature sensors for real-time monitoring of the temperature and corrosion of metal components, which are commonly used in coal-fired boilers. This study presents the development of cost-effective wireless high-temperature sensors for real-time temperature and corrosion monitoring in coal-fired boilers' metal components. The focus is on fabricating and evaluating chipless radio-frequency identification (RFID) sensors capable of operating between 25-1300 ºC. Efforts were directed towards designing passive RFID sensor and interrogator antenna with a broad frequency range, optimizing a microstrip patch antenna sensor integrated into a "peel-and-stick" format for efficient application to various metal specimens without altering their geometry. Additionally, this research aimed to assess the sensor responses under accelerated high-temperature conditions, correlating corrosion and cracking mechanisms with sensor data. An investigation of through-wall data acquisition techniques was also planned, facilitating unobtrusive monitoring of sensor responses housed within metal enclosures. Ultimately, this work sought to establish a robust passive wireless sensor system for the continuous health monitoring of metal components in operational settings, thereby contributing to enhanced safety and efficiency in coal-fired power plants.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2021

All-Digital Plug and Play Passive RFID Sensors for Energy Efficient Building Control

This is the final report for the project “All-Digital Plug and Play Passive RFID Sensors for Energy Efficient Building Control”, funded by DOE, and performed by Clemson University, Phase IV Engineering and Harvard University from October 1, 2016 to December 31, 2020. The main objective of this project is to develop, demonstrate and pre-commercialize a novel, plug & play, battery-free, wireless sensor technology to enable low-cost (<$10 per node) indoor and outdoor temperature and humidity measurement for energy efficient building controls and operations. The proposed technology is based on the novel concept of all-digital sensing and its seamless integration with the passive RFID technology. This project focuses on the design, fabrication, material optimization, interrogation electronics, validation, and demonstration of the novel sensor nodes for building applications. The specific objectives of this research program include: (1) Design, fabricate and optimize a compact, robust, and high-resolution digitizer, which could convert rotation angle into digital numbers. (2) Develop the multi-physics-based modeling and simulation of the temperature/humidity transducer to derive a rational design of the architecture, dimension, structure, materials (i.e., mechanical, electrical, thermal and hygroscopic) properties and functions of the sensor node. (3) Design, fabricate and optimize the bi-material based humidity sensitive coil which could linearly transduce the environmental relative humidity variations to rotation angles. (4) Design, fabricate and optimize an UHF RFID platform which could support long-range passive wireless communications of 8-bit digital numbers. (5) Design, fabricate and optimize the miniaturized all-digital sensor using MEMS technology. (6) Validate the integrated all-digital sensing system in a real building environment to test the system’s performance.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Wireless Passive Ceramic Sensor for Far-Field Temperature Measurement at High Temperatures

A passive wireless high-temperature sensor for far-field applications was developed for stable temperature sensing up to 1000 °C. The goal is to leverage the properties of electroceramic materials, including adequate electrical conductivity, high-temperature resilience, and chemical stability in harsh environments. Initial sensors were fabricated using Ag for operation to 600 °C to achieve a baseline understanding of temperature sensing principles using patch antenna designs. Fabrication then followed with higher temperature sensors made from (In, Sn) O2 (ITO) for evaluation up to 1000 °C. A patch antenna was modeled in ANSYS HFSS to operate in a high-frequency region (2.5–3.5 GHz) within a 50 × 50 mm2 confined geometric area using characteristic material properties. The sensor was fabricated on Al2O3 using screen printing methods and then sintered at 700 °C for Ag and 1200 °C for ITO in an ambient atmosphere. Sensors were evaluated at 600 °C for Ag and 1000 °C for ITO and analyzed at set interrogating distances up to 0.75 m using ultra-wideband slot antennas to collect scattering parameters. The sensitivity (average change in resonant frequency with respect to temperature) from 50 to 1000 °C was between 22 and 62 kHz/°C which decreased as interrogating distances reached 0.75 m.

47 OTHER INSTRUMENTATION↗
DOE OSTI2023

Redox-enabled electronic interrogation and feedback control of hierarchical and networked biological systems

Abstract Microelectronic devices can directly communicate with biology, as electronic information can be transmitted via redox reactions within biological systems. By engineering biology’s native redox networks, we enable electronic interrogation and control of biological systems at several hierarchical levels: proteins, cells, and cell consortia. First, electro-biofabrication facilitates on-device biological component assembly. Then, electrode-actuated redox data transmission and redox-linked synthetic biology allows programming of enzyme activity and closed-loop electrogenetic control of cellular function. Specifically, horseradish peroxidase is assembled onto interdigitated electrodes where electrode-generated hydrogen peroxide controls its activity. E. coli ’s stress response regulon, oxyRS , is rewired to enable algorithm-based feedback control of gene expression, including an eCRISPR module that switches cell-cell quorum sensing communication from one autoinducer to another—creating an electronically controlled ‘bilingual’ cell. Then, these disparate redox-guided devices are wirelessly connected, enabling real-time communication and user-based control. We suggest these methodologies will help us to better understand and develop sophisticated control for biology.

59 BASIC BIOLOGICAL SCIENCES↗