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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 OSTI2021

A probability density function model describing height estimation uncertainty due to image pixel intensity noise in digital fringe projection measurements

Digital fringe projection is a surface-profiling technique used for highly accurate non-contact measurements. As with any measurement technique, a variety of sources degrade to the measurement accuracy of the method. Here, this paper presents an analytically-derived probability density function that explicitly models the surface height measurement error due to inevitable phase measurement error, and it includes the specific case of pixel noise inducing the phase measurement error that ultimately leads to the height estimation error. The accuracy of the model was validated through Monte-Carlo simulations of resultant height distributions subject to arbitrarily correlated pixel intensity noise and experimental digital fringe projection measurements where the pixel-by-pixel height uncertainty estimations were compared to the predictions of the derived model.

42 ENGINEERING↗
DOE OSTI2022

A systematic study and framework of fringe projection profilometry with improved measurement performance for in-situ LPBF process monitoring

Fringe Projection Profilometry (FPP) is a cost-effective and non-invasive technology that has been shown to measure finer features. Here, in this work, we developed an in-situ FPP method to measure the dynamic topography of powder bed and printed layer during Laser Powder Bed Fusion (LPBF) additive manufacturing (AM) process. A systematic study towards developing a comprehensive framework of LPBF-specific FPP is demonstrated to enhance and evaluate the performance of applying FPP for in-situ LPBF monitoring, including 1) a modified sensor model with localized correction; 2) improved phase unwrapping with FFT filtering 3) quantitative uncertainty analysis; and 4) experimental validation with ex-situ characterization. The developed LPBF-specific FPP system and methods are implemented on a commercial LPBF-AM machine, achieving better accuracy, more robustness, and increased field of view while maintaining sufficient measurement range and decent resolution, in contrast to literature methods. The established FPP framework will facilitate the development of closed-loop control strategies for advancing LPBF based AM.

42 ENGINEERING↗
DOE OSTI2023

Project Fringe, Testing and Validation on Metal Additive Manufacturing

Oak Ridge National Laboratory (ORNL) worked with Additive Monitoring Systems (AMS) to demonstrate the real-time inspection of additive manufacturing (AM) binder jet fusion 3D printing (BJF). Test coupons on the ExOne Innovent were printed and monitored using AMS’s Project Fringe structured light system. Anomalies were detected automatically and classified post build as recoater powder layer non-uniformities, binder powder interaction, depressions, and sub optimal print area. These anomalies were not apparent in the visual spectrum, which suggests that the structured light system has advanced the monitoring techniques state-of-the-art for BJF.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Effects of digital fringe projection operational parameters on detecting powder bed defects in additive manufacturing

Additive manufacturing is a technology transforming traditional production timelines. Specifically, metal additive manufacturing (MAM) has been increasingly adopted by a variety of industries, not only to prototype, but also to fulfill full production scale applications with much lower lead times. Like any maturing manufacturing technology, developments in verifying and validating processes are necessary to support continuous growth. Due to the complex nature of MAM, part quality and repeatability remain integral challenges that inhibit further adoption of MAM for critical component production. In this study, we present data taken from a developing in-process monitoring system designed to measure and detect powder bed defects (PBDs) in powder bed fusion MAM systems using surface height maps created with structured light illumination. We showcase the feasibility of the monitoring technique for in-process implementation by detecting streak PBDs with varying severities (height, width) created in a lab environment. We present results of powder bed measurements for varying experimental parameters of the structured light system such as illumination angle, illumination pattern, and number of illuminations. We also present an expression used to determine experimental height noise based on input parameters for PBD detection based on the instrument transfer function of the structured light monitoring system for arbitrary pixel intensity noise contributions. In conclusion, with the results of PBD detection across multiple experimental measurement parameters, we provide a best practices approach to in-process implementation of the monitoring system in powder bed fusion manufacturing.

36 MATERIALS SCIENCE↗
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 OSTI2023

Feasibility of a Novel Density Functional Method Outside the Kohn-Sham Framework for Modeling Global Potential Energy Surfaces of Molecular Chemical Reactions (Final Technical Report)

The project aimed towards the construction of computational methods capable of modeling the global potential energy surface (PES) of small molecules, molecular ions, and radicals — including the parts of the PES which correspond to chemical reactions, and the reaction paths connecting reactants, intermediates, and reaction products. This goal may seem humble at first glance, but for chemical systems with more than about six atoms in total, at the time the project was proposed, there were no established theoretical methods capable of simulating such systems reliably, not even for small molecules in the gas phase which are electronically benign. This restriction severely hampers our ability to model and control chemical processes under harsh conditions. With the goal of constructing a method capable of modeling such chemical systems, we proposed to pursue a novel approach towards a Multi-Configuration (MC) DFT outside the traditional frameworks of Kohn-Sham theory and other methods of coupling wave function theory with DFT. Rather than being a complete active space (CAS) method, the proposed DOCI-DFT would employ a special restricted form of the active space wave function, called Doubly-Occupied CI (DOCI)—this wave function form is sufficient to describe not only heterolytic, but also homolytic bond dissociation processes at the zeroth order (i.e., as active space wave function). There are no other standard mean field methods which can do so. In the original proposal, we also outlined strong formal and practical arguments speaking for this method. The project proposal was accepted by the Department of Energy and provided two years of seed funding for one graduate student, as well as two years of two weeks PI summer-salary for the PI. However, ultimately the project could not be effectively pursued due to severe interferences outside the context scientific problems and was cancelled. Apart from two weeks of PI salary (and associated fringe & overhead costs issues by the performing institution), no costs were charged against the award, with the entire rest of funding returned to the Department of Energy. This report reiterates the primary background information regarding the project, its original goals, and outlines the preliminary work performed during the two weeks of DOE funding charged.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
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 OSTI2023

Statistical Generation of Ocean Forcing With Spatiotemporal Variability for Ice Sheet Models

Melting of ice at the base of floating ice shelves that fringe the Antarctic ice sheet has been identified as a significant source of uncertainty in sea level rise projections. Part of this uncertainty derives from chaotic internal variability of the coupled ocean-atmosphere system. For numerical ice sheet model projections, this uncertainty has not previously been quantified because of the prohibitive computational expense of running large climate model ensembles. Here, we develop and demonstrate a technique that generates independent realizations of internal climate variability from a single climate model simulation. Building on previous developments in model emulation, this technique uses empirical orthogonal function decomposition and Fourier-phase randomization to generate statistically consistent realizations of spatiotemporal variability fields for the target climate variable. The method facilitates efficient sampling of a wide range of climate trajectories, which can also be incorporated within ice sheet or other physical models to represent feedback processes.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

Urban morphology and urban water demand: a case study in the land constrained Los Angeles region using urban growth modeling

The interactions between population growth, urban morphology, and water demand have important implications for water resources and supply in urban regions. Water use for irrigation comprises a significant fraction of urban water demand, and is potentially influenced by long-term changes in urban morphology. To investigate this, we used spatially explicit projections of urban land development intensity (fraction impervious area) generated from a 30 m resolution urban growth model for the Los Angeles (LA) region. Recent historical data on water use and high resolution landcover were used to establish relationships between green area, urban development intensity, and outdoor water demand. These relationships were then used to project outdoor and total water demand in 2100 using the urban growth model outputs. We considered two different population scenarios informed by the shared socioeconomic pathway (SSP) projections for the region (SSP3 and SSP5), and three scenarios of urban development intensification. Our analysis is resolved for over 80 water providers in the region, from the urban core to suburban fringe, and highlights diverse demand responses influenced by initial urban form and water demand attributes. Assumptions about outdoor water use factors based on recent water supply data were found to be nearly as influential on future outdoor demand as the urban growth scenario settings. Compared to previous studies, our work is unique in coherently linking high resolution SSP population scenarios, urban land cover evolution, and urban water demand projections, demonstrating the approach for the LA region—the largest population center in the western United States.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

Grid-Forming Inverters: Project Demonstrations and Pilots

Power system operators around the world are pushing the limits of integrating inverter-based resources (IBRs) to very high levels, approaching 100% instantaneous penetration under certain operating conditions. This often applies to smaller power systems with very little or no ac interconnections to other neighboring regions or sometimes to fringes of large balancing areas, such as Denmark or Portugal, within the mainland European power system. These jurisdictions have identified the potential of grid-forming (GFM) technology as a key enabler to support the energy transition with very few or no synchronous generators online. Until recently, practical applications of GFM inverters were limited to microgrids and isolated grids and in smaller grid applications on the order of a few tens of megawatts (MW).

Australia↗
DOE OSTI2023

Fringe field maps for symplectic models of general Cartesian dipoles

We present a framework with which to analyze the effects of magnetic fringe fields. The theory defines the fringe field to be the transition between two regions of nearly constant field, and can incorporate constant multipoles in the magnet body. We then analyze Cartesian dipoles and derive symplectic fringe field maps that are applicable to longitudinal and/or transverse gradient dipoles. We verify the fringe maps with tracking, and show how we incorporated the theory into the tracking code ELEGANT. The resulting elements and several supporting scripts are now available for users, and we conclude with several predictions relevant to the APS Upgrade project.

43 PARTICLE ACCELERATORS↗
DOE OSTI2022

Ionization-Based Optical Structures for the Control of Short-Pulse Lasers (Abbreviated LDRD Report)

The intensity of light from the highest-power lasers is limited by the size of the optics required to amplify, compress, transport, and focus a laser beam. Indeed, optics damage puts strict constraints on the laser energy density that solid optics can sustain; this leads to enormous optics sizes and limits the maximum intensity that these lasers can achieve. In this project we investigated new types of diffractive optics based on mixtures of neutral gas and plasmas. The basic idea is to interfere laser beams in a gas near the ionization threshold, so that plasma is created in the constructive interference regions (i.e., the “bright” fringes of the interference pattern) while the destructive interference regions remain a neutral gas. The resulting refractive index modulation, due to the different indices in gas vs. plasma, effectively turns such structures into diffractive optics elements. We proposed several new types of optics based on this general concept: i) reflection gratings, which can act as mirrors of “pulse cleaners” to eliminate laser pre-pulse; ii) transmission gratings, as part of a new type of pulse compression scheme with the potential to achieve laser intensities orders of magnitude above what is currently feasible using solid-state optics; and iii) holographic lenses, to focus high-power lasers. We conducted laboratory experiments which demonstrated high efficiency reflection gratings, paving the way for practical applications of our new concepts.

47 OTHER INSTRUMENTATION↗
DOE OSTI2024

In-line, High-Throughput Quality Monitoring for Fuel Cell and Electrolyzer Components Based on Transmission and Reflection Imaging

During the manufacturing of fuel cell and electrolyzer membranes and membrane electrode assemblies (MEAs), real-time, in-line, high-throughput optical-based quality monitoring methods are essential for detecting defects and monitoring thickness variations, thus improving the performance and increasing the durability of fuel cell and electrolyzer in the hydrogen industry. For the MEAs with very opaque coatings, optical transmission-based imaging has been developed and applied in the Roll-to-Roll system using a flashlight and a high-sensitivity CCD camera. We observed high signal-to-noise ratio images while the Roll-to-Roll system ran at 5 ft/min. The entire sample image could quickly be recovered from the discrete frames using customized Python codes for automatic frame cropping and stitching. We detected significant non-uniformities in our experimental MEAs specimen. For fuel cell and low-temperature electrolysis (LTE) transparent membranes, we used optical reflectance hyperspectral imaging with interference fringe-based thickness mapping. We set up a hyperspectral camera to measure various rolls of commercial membranes. The measurement results are analyzed to find the thickness distribution of each roll and to check for defects. Transmission and reflection imaging-based quality monitoring techniques demonstrated in this project can be widely used in the mass production environment to improve the production yield and performance of hydrogen devices.

DIRECT ENERGY CONVERSION,ENGINEERING↗
DOE OSTI2020

Conceptual Design of DUNE Near Detector Superconducting Magnet System

The Deep Underground Neutrino Experiment (DUNE) has formed a near detector design group (NDDG) tasked with delivering a CDR by the end of 2019. The DUNE Near Detectors will be housed in an underground hall on the Fermilab site. The two main detector systems are a liquid argon detector and a high-pressure gas time projection chamber (HPgTPC). The HPgTPC requires a magnet that generates a 0.5 T solenoidal magnetic field in a large volume of 6 m diameter, and 5 m length. Herein, we present a superconducting magnet system design. We investigated: an open air core magnet with three coils, and a five coils system having two active fringe field shielding coils. Coils positions were optimized to obtain the specified field homogeneity in the magnet good field region, while minimizing the Lorentz forces and the superconductor volume. We discuss the magnetic, mechanical, and thermal conceptual designs.

43 PARTICLE ACCELERATORS↗
DOE OSTI2021

3D Mechanical Analysis of a Compact Nb 3 Sn IR Quadrupole for EIC

Abstract-The Electron Ion Collider (EIC) will require large aperture quadrupole magnets for the Hadron beam in the insertion region. Key requirements include high field, compact size, and tight control of the fringe fields. A 120 mm aperture, 308.4 mm outer diameter actively shielded Nb 3 Sn quadrupole model is under development to support these goals. This work is being carried out by a collaboration of BNL, JLAB and LBNL. A compact shell-based structure preloaded with a bladder and key system was developed for this project. In this paper, the effect of the compact structure on the mechanical behavior was investigated. In particular, the impact of the assembly tolerances and coil size variations on the actual coil stresses and bladder pressures was computed and compared with results from larger bladder and key structures developed for the LHC IR. The longitudinal preload is provided by stainless steel rods. Differently from other bladder and key magnets, the rods are first preloaded axially before coil axial load is applied. This new design aims to increase the overall stiffness of the system and reduce the longitudinal coil displacement during powering. Based on the results of a 3D mechanical analysis, the preliminary preload targets for the EIC quadrupole assembly will be reviewed and discussed.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2023

Baltimore Ecosystem Study: Stream chemistry for core sites in Gwynns Falls

In the Baltimore urban long-term ecological research (LTER) project, (Baltimore Ecosystem Study, BES) we use the watershed approach to evaluate integrated ecosystem function. The LTER research is centered on the Gwynns Falls watershed, a 17,150 ha catchment that traverses a gradient from the urban core of Baltimore, through older urban residential (1900 - 1950) and suburban (1950- 1980) zones, rapidly suburbanizing areas and a rural/suburban fringe. Our long-term sampling network includes four longitudinal sampling sites along the Gwynns Falls as well as several small (40 - 100 ha) watersheds located within or near to the Gwynns Falls. The longitudinal sites provide data on water and nutrient fluxes in the different land use zones of the watershed (rural/suburban, rapidly suburbanizing, old suburban, urban core) and the small watersheds provide more focused data on specific land use areas (forest, agriculture, rural/suburban, urban). Each of the gaging sites is continuously monitored for discharge and is sampled weekly for chemistry. Additional chemical sampling is carried out in a supplemental set of sites to provide a greater range of land use. Weekly analyses includes nitrate, phosphate, total nitrogen, total phosphorus, chloride and sulfate, turbidity, fecal coliforms, temperature, dissolved oxygen and pH. Cations, dissolved organic carbon and nitrogen and metals are measured on selected samples. Streamflow data for this site are posted at: http://waterdata.usgs.gov/md/nwis/nwisman?site_no=015835701

Groffman, Peter M (ORCID:0000000183716255)↗
DOE OSTI2022

Modeling and implementation of vertical excursion FFA in the Zgoubi ray-tracing code

Vertical Fixed Field Accelerators (vFFAs) feature complex and highly non-linear magnetic fields, which require simulation codes allowing step-wise particle tracking. Methods to model the 3D magnetic field of scaling vFFAs have been developed in the ray-tracing code Zgoubi. The field modeling and particle tracking methods include the field non-linearities, the fringe fields, and the field superposition of neighboring magnets. The procedure implements the vFFA analytical field expressions, allowing design studies and parameter optimizations using the Zgoubi built-in fit method. The vFFA procedure has been applied to a ten-fold symmetry ring with a triplet focusing structure designed to accelerate protons from 3 MeV to 12 MeV and studied under the ISIS-II proton driver prototype project. Results from particle tracking in externally generated 3D semi-analytical field maps and the developed vFFA analytical model are shown to be in excellent agreement.

43 PARTICLE ACCELERATORS↗