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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 OSTI2022

Light Water Reactor Sustainability Program: Complete the weld campaign on Ni-base irradiated materials using stress improved laser welding including the preliminary weld quality inspections

This report summarizes the most recent welding campaign on irradiated Ni-base alloy 182 and the preliminary weld quality inspections at the Radiochemical Engineering Development Center (REDC). Equipment and capabilities were developed jointly by the U.S. Department of Energy, Office of Nuclear Energy, Light Water Reactor Sustainability Program, the Electric Power Research Institute, Long Term Operations Program (and the Welding and Repair Technology Center), and Oak Ridge National Laboratory. Irradiated nickel alloy 182, with target helium contents of 5 atom parts-per million (appm), 10 appm, and 20 appm, were laser welded in the hot cell successfully. The significant, on-going effort to weld irradiated alloys with high helium concentrations and comprehensively analyze the results will eventually yield validated repair techniques and guidelines for use by the nuclear industry in extending the operational lifetimes of nuclear power plants. This report fulfills the FY 2023 milestone M3LW-22OR0406013, “Complete the weld campaign on Ni base irradiated materials using stress improved laser welding including the preliminary weld quality inspections”.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS1979

Grain quality inspection system

A review of grain quality indicators and measurement methods was conducted in order to assess the feasibility of using remote sensing technology to develop a continuous monitoring system for use during grain transfer operations. Most detection methods were found to be too slow or too expensive to be incorporated into the normal inspection procedure of a grain elevator on a continuous basis. Two indicators, moisture content and broken corn and foreign material, show potential for automation and are of an economic value. A microprocessor based system which utilizes commercially available electronic moisture meter was developed and tested. A method for automating BCFM measurement is described. A complete system description is presented along with performance test results.

Flood, C. A., Jr.↗
DOE OSTI2021

Collaboration on SBIR/TTO Phase II Project for Optical QC Device and Collaboration on SBIR/TTO Phase II-b Project for Advanced Quality Inspection Device Development: Cooperative Research and Development CRADA Number CRD-16-00652 (Final Report)

The overall goal of this program is to develop and commercialize a turnkey quality control solution for the entire PEM fuel cell manufacturing process including membrane, gas diffusion layers, catalyst, and assembled systems. This quality control solution is unique to each customer’s specific needs but includes a suite of in-line quality control systems for roll-to-roll manufacturing that can target thin, transparent membrane as well as opaque membrane, catalyst, and GDLs. The Phase II developed the CPNUVV system for thin, transparent membrane that operates using polarized filters to enhance defect resolution and determine thickness. However, PEM material manufacturers want a complete, turnkey solution for all components of the PEM fuel cell. In the Phase IIB, Mainstream will partner with NREL, and transition reflectance technology NREL developed (US Patent 9,234,843) to operate in real-time on a web-line to develop a total solution to PEM quality control. The device will identify and mark defects as well as monitor materials thickness in real-time to improve line efficiency and to reduce waste. The research performed at NREL under this CRADA increases the basis of knowledge about optical inspection methods, how they perform with regards to fuel cell component materials, and how they can be implemented in in-line, real-time configurations to provide quality inspection for roll-to-roll (R2R) manufacturing. Methods explored were found to be sensitive to catalyst loading in electrodes on both membrane and gas diffusion media substrates and to membrane thickness, across a broad range of thickness. The latter capability is novel and now patented and provides a previously unstudied and undemonstrated capability for R2R manufacturing of membranes.

30 DIRECT ENERGY CONVERSION↗
NASA NTRS1966

Ultrasonic quality inspection of bonded honeycomb assemblies is automated

Inspection system for bonded honeycomb assemblies is accurate, fast, and automated. The ultrasonic system consists of inner and outer transducer positioning assemblies with suitable motor controls, a centerless turntable assembly, water squirter assemblies, and an inspection program completely encoded on tape suitable for use on a high speed computer.

Kammerer, C. C.↗
NASA NTRS1983

Guidelines for software inspections

Quality control inspections are software problem finding procedures which provide defect removal as well as improvements in software functionality, maintenance, quality, and development and testing methodology is discussed. The many side benefits include education, documentation, training, and scheduling.

Source record↗
NASA NTRS2011

System Enhancements for Mechanical Inspection Processes

Quality inspection of parts is a major component to any project that requires hardware implementation. Keeping track of all of the inspection jobs is essential to having a smooth running process. By using HTML, the programming language ColdFusion, and the MySQL database, I created a web-based job management system for the 170 Mechanical Inspection Group that will replace the Microsoft Access based management system. This will improve the ways inspectors and the people awaiting inspection view and keep track of hardware as it is in the inspection process. In the end, the management system should be able to insert jobs into a queue, place jobs in and out of a bonded state, pre-release bonded jobs, and close out inspection jobs.

inspection processes↗
NASA NTRS1975

Design and development of polyphenylene oxide foam as a reusable internal insulation for LH2 tanks

Material specification and fabrication process procedures for foam production are presented. The properties of mechanical strength, modulus of elasticity, density and thermal conductivity were measured and related to foam quality. Properties unique to the foam such as a gas layer insulation, density gradient parallel to the fiber direction, and gas flow conductance in both directions were correlated with foam quality. Inspection and quality control tests procedures are outlined and photographs of test equipment and test specimens are shown.

Source record↗
NASA NTRS2011

Image Quality Indicator for Infrared Inspections

The quality of images generated during an infrared thermal inspection depends on many system variables, settings, and parameters to include the focal length setting of the IR camera lens. If any relevant parameter is incorrect or sub-optimal, the resulting IR images will usually exhibit inherent unsharpness and lack of resolution. Traditional reference standards and image quality indicators (IQIs) are made of representative hardware samples and contain representative flaws of concern. These standards are used to verify that representative flaws can be detected with the current IR system settings. However, these traditional standards do not enable the operator to quantify the quality limitations of the resulting images, i.e. determine the inherent maximum image sensitivity and image resolution. As a result, the operator does not have the ability to optimize the IR inspection system prior to data acquisition. The innovative IQI described here eliminates this limitation and enables the operator to objectively quantify and optimize the relevant variables of the IR inspection system, resulting in enhanced image quality with consistency and repeatability in the inspection application. The IR IQI consists of various copper foil features of known sizes that are printed on a dielectric non-conductive board. The significant difference in thermal conductivity between the two materials ensures that each appears with a distinct grayscale or brightness in the resulting IR image. Therefore, the IR image of the IQI exhibits high contrast between the copper features and the underlying dielectric board, which is required to detect the edges of the various copper features. The copper features consist of individual elements of various shapes and sizes, or of element-pairs of known shapes and sizes and with known spacing between the elements creating the pair. For example, filled copper circles with various diameters can be used as individual elements to quantify the image sensitivity limit. Copper line-pairs of various sizes where the line width is equivalent to the spacing between the lines can be used as element-pairs to quantify the image resolution limit.

Burke, Eric↗
NASA NTRS2018

Printed Circuit Board Inspection and Quality Control - PCB Failure Causes and Cures

This two day workshop will discuss a range of topics, including root cause analysis, physics-of-failure principles and failure mechanisms in printed circuit boards. Printed circuit boards (PCBs) are the baseline for electronics manufacturing upon which electronic components are mounted and formed into electronic systems. PCBs are used in a variety of electronic circuits from simple one-transistor amplifiers to large super computers. A PCB serves three main functions: 1) it provides the necessary mechanical support for the components in the circuit 2) it provides the necessary electrical interconnections, and 3) it bears some form of legend which identifies the components it carries. The failure modes on the PCBs can be categorized in a hierarchical structure, in which the mechanisms and causes are site or location dependant. Specimen preparation techniques, non-destructive and destructive analysis, and materials characterization will also be discussed. The first day of the workshop will present methodologies for identifying potential failure mechanisms in electronics based on the failure history and, systematic approaches to root cause analysis. The second day will cover failure analysis techniques geared towards various failure mechanisms, along with numerous component and PCB assembly failure analysis case studies that illustrate the techniques and analysis. Failure analysis case studies will be used to illustrate the techniques and analysis principles to arrive at the root cause(s) of field failures on printed circuit boards, active components, and assemblies.

Printed circuit boards↗
NASA NTRS1992

WELDSMART: A vision-based expert system for quality control

This work was aimed at exploring means for utilizing computer technology in quality inspection and evaluation. Inspection of metallic welds was selected as the main application for this development and primary emphasis was placed on visual inspection, as opposed to other inspection methods, such as radiographic techniques. Emphasis was placed on methodologies with the potential for use in real-time quality control systems. Because quality evaluation is somewhat subjective, despite various efforts to classify discontinuities and standardize inspection methods, the task of using a computer for both inspection and evaluation was not trivial. The work started out with a review of the various inspection techniques that are used for quality control in welding. Among other observations from this review was the finding that most weld defects result in abnormalities that may be seen by visual inspection. This supports the approach of emphasizing visual inspection for this work. Quality control consists of two phases: (1) identification of weld discontinuities (some of which may be severe enough to be classified as defects), and (2) assessment or evaluation of the weld based on the observed discontinuities. Usually the latter phase results in a pass/fail judgement for the inspected piece. It is the conclusion of this work that the first of the above tasks, identification of discontinuities, is the most challenging one. It calls for sophisticated image processing and image analysis techniques, and frequently ad hoc methods have to be developed to identify specific features in the weld image. The difficulty of this task is generally not due to limited computing power. In most cases it was found that a modest personal computer or workstation could carry out most computations in a reasonably short time period. Rather, the algorithms and methods necessary for identifying weld discontinuities were in some cases limited. The fact that specific techniques were finally developed and successfully demosntrated to work illustrates that the general approach taken here appears to be promising for commercial development of computerized quality inspection systems. Inspection based on these techniques may be used to supplement or substitute more elaborate inspection methods, such as x-ray inspections.

Andersen, Kristinn↗
DOE OSTI2022

MEA Manufacturing R&D

This is our annual presentation on the HFTO-funded MEA Manufacturing R&D project, mainly focused on development of in-line quality inspection methods for high volume fabrication of fuel cell and electrolysis MEA materials.

DIRECT ENERGY CONVERSION,ENGINEERING↗
DOE OSTI2025

Membrane Electrode Assembly Manufacturing Automation Technology for the Electrochemical Compression of Hydrogen: Cooperative Research and Development (Final Report)

Electrochemical compression has the possibility to outcompete mechanical compression for hydrogen end- use applications. While HyET has a compressor that can output JO kilograms (kg)/day (fully scalable from home-to-industrial application) at up to 700 bar, the energy demand and reliability require top-quality electrochemical hydrogen compression (EHC) membrane electrode assemblies (MEAs), preferably prepared by cost-effective high-capacity manufacturing. High pressure requires a special MEA design, deviating from typical proton exchange membrane fuel cell (PEMFC) MEAs with adapted catalyst layer substrates, asking for a modified coating process. The National Renewable Energy Laboratory (NREL) will help HyET by developing an automated catalyst coating process fit for EHC MEA manufacturing. In addition, inline quality inspection methods will be developed/selected to improve the MBA quality as it is used for EHC stack assembly. In a joint effort, NREL and HyET will even design an automated manufacturing process for the EHC MEA and approach potential United States (US) suppliers of manufacturing equipment.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2022

Vision-based inspection of prefabricated components using camera poses: Addressing inherent limitations of image-based 3D reconstruction

Modular construction can lead to additional cost overruns and delays when a defect is found on the construction site and is not easily repairable. Researchers have developed various methods that use image-based 3D reconstruction for quality assessment, but they have inherent limitations, such as inconsistency and dealing with surfaces with reflectivity and limited visual features. Therefore, this paper presents a vision-based quality assessment method using cameras for prefabricated components by addressing these limitations. Specifically, this paper proposes a novel quality inspection method with sub-millimeter accuracy using cameras focused on leveraging camera poses (as opposed to 3D point clouds that are often not consistent in quality) from the image-based 3D reconstruction. The 3D point estimation by computing triangulation was used for achieving accurate measurement. The proposed method is validated using six different variances and two case studies – an aluminum pipe with a reflective surface and a fabricated concrete column. Furthermore, the results demonstrate the accuracy and effectiveness of the proposed method.

42 ENGINEERING↗
NASA NTRS1972

Testing methods and techniques: Quality control and nondestructive testing: A complication

A variety of devices and techniques useful in nondestructive testing is described. Ranging in complexity from an automated ultrasonic testing system designed for complex laminated honeycomb structures, to a flexible leak detector probe, the items represent either potential savings in cost and time, or improvement in inspection quality over past techniques. Data cover weld and braze inspection, leak detection, and inspection of composite materials.

Source record↗
NASA NTRS1982

Advanced manufacturing development of a composite empennage component for L-1011 aircraft

This is the final report of technical work conducted during the fourth phase of a multiphase program having the objective of the design, development and flight evaluation of an advanced composite empennage component manufactured in a production environment at a cost competitive with those of its metal counterpart, and at a weight savings of at least 20 percent. The empennage component selected for this program is the vertical fin box of the L-1011 aircraft. The box structure extends from the fuselage production joint to the tip rib and includes front and rear spars. During Phase 4 of the program, production quality tooling was designed and manufactured to produce three sets of covers, ribs, spars, miscellaneous parts, and subassemblies to assemble three complete ACVF units. Recurring and nonrecurring cost data were compiled and documented in the updated producibility/design to cost plan. Nondestruct inspections, quality control tests, and quality acceptance tests were performed in accordance with the quality assurance plan and the structural integrity control plan. Records were maintained to provide traceability of material and parts throughout the manufacturing development phase. It was also determined that additional tooling would not be required to support the current and projected L-1011 production rate.

Alva, T.↗
DOE OSTI2024

Review of In Situ Sensing for Directed Energy Deposition for Industrial Part Quality Assessment

As the use additive manufacturing (AM) processes continues to grow in critical industries, improved quality assurance methods are becoming increasingly sought after for qualification and certification of AM components. Traditional nondestructive evaluation of printed components is often unable to supply the required confidence in print quality to justify qualification and certification, but the layer-by-layer nature of AM provides unprecedented opportunities for in situ quality inspection. This document summarizes recent developments in process monitoring research specifically related to Directed Energy Deposition (DED). Particular attention is given to three aspects of the highlighted manuscripts: (1) the type of sensors used, (2) features extracted from each sensor modality, and (3) analysis of extracted features for AM quality assessment. Based on the review of the state-of-the-art, several observations have been made. First, none of the reviewed works have applied their trained models to real part geometries, with many of the works relying on single track experiments, thin-walled structures, and cubes. Similarly, there have not been any works demonstrating model generalizability, i.e., a model trained on data from one build allows for fruitful analysis of data from another build. Many works used machine learning techniques to distinguish different process regimes (i.e., normal, keyholing, lack-of-fusion), but very few papers have investigated stochastic variation in an already “optimized” process. Sensor fusion approaches are also limited in the DED sensing literature, but the few works that have employed such techniques have demonstrated the benefits. Finally, registration of in situ data to the build coordinate system is of paramount importance to producing industrially relevant in situ monitoring systems. Data registration allows direct correlations between process anomalies detected in the process monitoring data to localized departures in part quality, but such techniques are generally lacking in the current literature.

36 MATERIALS SCIENCE↗