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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

Calibration approach and range of observed sap flow influences transpiration estimates from thermal dissipation sensors

Calibrating thermal dissipation (TD) sap flow sensors has become increasingly important to accurately estimate whole-tree transpiration, but it is unclear how the calibration approach itself influences the resulting coefficients and estimates. Here, we compare the two most common calibration approaches, gravimetric and potometric, using TD sensors inserted into Eucalyptus benthamii tree stems. The gravimetric approach uses an excised stem segment devoid of branches and leaves and pushes water through the stem using gravity, a positive force. The potometric approach uses a severed stem containing an intact canopy placed upright in a reservoir where water is pulled through the stem via transpiration, a negative force. We hypothesized that the positive pressure associated with gravimetric calibration would overestimate conductive sapwood area relative to that estimated from potometric calibration and that coefficients from these different approaches would result in different estimates of transpiration when applied to intact trees. We also predicted that calibrations could improve transpiration estimates by targeting the range of observed sap flow rates (i.e., K values) in intact trees. Conductive sapwood area was higher under gravimetric calibrations and resulting estimates of transpiration were lower compared to potometric calibrations. Segmented calibration curves, which fit two separate curves for the relationship between sap flux density (Fd) and sap flux index (K) based on the range of sap flow rates observed in intact trees, increased transpiration estimates from both gravimetric and potometric coefficients and diminished the magnitude of difference in transpiration estimates between approaches. Researchers should be aware that calibration approach and range of observed sap flow profoundly influences transpiration estimates from TD sensors and this likely applies to calibrations of other heat-based sap flow sensors.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

Aerosol jet printed 3 omega sensors for thermal conductivity measurement

The 3 omega (3ω) method is a trusted technique for measuring thermal conductivity—a fundamental material property of critical importance in a broad range of applications. However, traditional 3ω sensor processing requires some form of physical vapor deposition, such as metal evaporation or sputtering. These 3ω sensor deposition techniques limit the materials and sample sizes applicable to the 3ω method. This work demonstrates an aerosol jet printing method to directly print silver 3ω sensors that yield accurate temperature-dependent measurement up to 300 °C on materials with thermal conductivity ranging from 1 to 150 W/m K. The interrelationship between printed sensor geometry, sensor thermal stability, and applicability to the 3ω method is examined. Thermal conductivity measurement with 3ω sensors conventionally sintered at 300 °C agrees to independent laser flash measurement within 4% from room temperature to 150 °C. An unconventional rapid high-temperature sintering method is shown to produce sensors that agree within 3% of the laser flash measurements from room temperature to 300 °C. The rapid sintering profiles also reduced the sensor–substrate thermal boundary resistance of the printed sensors by as much as 88%. The direct printing of 3ω sensors creates opportunities for measurement of thermal transport properties in applications previously inapplicable to the 3ω method.

47 OTHER INSTRUMENTATION↗
DOE OSTI2020

Thermal dissipation sensors enter a new age: Navigating frontiers in transpiration and hydrologic function

Thermal dissipation (TD) sensors have been used extensively for a wide array of sap flow applications, and yet recently several limitations of this approach have been identified, including a tendency to underestimate absolute flows, especially in small stems with very high flows. However, when used properly, the TD method remains the most cost effective and reliable approach for determining relative flows in comparison studies. Major advantages of this method include the ability to replicate maximally within trees, across trees of different sizes, and across multiple species to capture the full range of natural variation in the study system. From early studies, such variation has been deemed a major challenge for representing stand-level dynamics. In a series of recent comparison studies, we determined mean sap flux density dynamics within and among groups of trees. These studies were conducted within temperate coniferous forest (n=46), temperate oak savanna (n=36), temperate pine forest (n=49), temperate bottomland hardwood forest (n=23), tropical premontane rainforest (n=43), semiarid subtropical shrubland (n=25), and tropical dry forest (n=15), with a total of 237 sensors. Two study sites were also equipped with eddy covariance systems for determination of stand-level evapotranspiration. Sites subject to high background thermal gradients used the transient thermal dissipation method. Comparisons varied between studies but tended to focus on relative flow differences between species, between wetter and drier microsites, between understory and overstory components, or between wetter and drier periods of the growing season. Except for the shrubland sites, study trees tended to be at least 15-cm diameter and frequently exceeded 50-cm diameter. Results of this cross-site comparison highlight the inherent variation in natural stands and the importance of using large sample sizes. The TD approach remains a valuable and preferred method for the future determination of water use in trees. However, sensor replication can fundamentally impact a study's outcomes and should be more carefully considered in study design. Customized error mitigation strategies are best to address the sources of variation most problematic for a particular study. In conclusion, the development of “smart” calibration approaches that correct for fundamental effects of radial variation inherent in thermal dissipation studies is discussed.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2023

Nonintrusive thermal-wave sensor for operando quantification of degradation in commercial batteries

Abstract Monitoring real-world battery degradation is crucial for the widespread application of batteries in different scenarios. However, acquiring quantitative degradation information in operating commercial cells is challenging due to the complex, embedded, and/or qualitative nature of most existing sensing techniques. This process is essentially limited by the type of signals used for detection. Here, we report the use of effective battery thermal conductivity ( k eff ) as a quantitative indicator of battery degradation by leveraging the strong dependence of k eff on battery-structure changes. A measurement scheme based on attachable thermal-wave sensors is developed for non-embedded detection and quantitative assessment. A proof-of-concept study of battery degradation during fast charging demonstrates that the amount of lithium plating and electrolyte consumption associated with the side reactions on the graphite anode and deposited lithium can be quantitatively distinguished using our method. Therefore, this work opens the door to the quantitative evaluation of battery degradation using simple non-embedded thermal-wave sensors.

25 ENERGY STORAGE↗
DOE OSTI2025

Development of a High-Intensity Heat Flux Gauge and Characterization Facility (Final Report)

Sandia National Laboratories (SNL) and Hukseflux Thermal Sensors (HTS) collaborated to advance the design and calibration of high-intensity heat flux gauges capable of measuring 2500 kW/m². An industry trade study was first conducted and highlighted the need for enhanced gauge designs and calibration methodology & services suited for high-intensities and broadband flux. We then developed, tested, and evaluated three prototype gauge designs along with four distinct coating types, each designed to extend the measurable flux range of existing HTS products to higher intensity levels. Following a down selection process, the project team refined the focus to a final product design, incorporating updated features to enhance its robustness during high flux exposure.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2020

Sensors for measuring thermal conductivity and related methods

A sensor for measuring thermal conductivity includes an insulator, a test material over the insulator, a conductor over the test material, and a gas within an open volume adjacent the test material and the conductor. An electrical source is configured to provide an alternating current through the conductor to heat the test material. Leads are connected to the conductor and configured to connect to a voltmeter. A method of measuring thermal conductivity includes disposing the sensor in a reactor core in which a nuclear fuel undergoes irradiation and radioactive decay. An alternating current is provided from the electrical source through the conductor to heat the test material. A voltage is measured as a function of time at the leads connected to the conductor. A thermal conductivity of the test material is calculated based on the voltage measured as a function of time. Methods of forming a sensor are also disclosed.

Daw, Joshua↗
DOE OSTI2021

Fusion-based occupancy sensing for building systems

Sensing and control apparatus for a building HVAC system includes interior and boundary sensors, such as cameras and thermal sensors, generating sensor signals conveying occupancy-related features for an area. A controller uses the sensor signals to produce an occupancy estimate and to generate equipment-control signals to cause the HVAC system to supply conditioned air to the area based on the occupancy estimate. The controller includes fusion systems collectively generating the occupancy estimate by corresponding fusion calculations, the fusion systems producing a boundary occupancy-count change based on sensor signals from the boundary sensors, an interior occupancy count based on sensor signals from the interior sensors, and the overall occupancy estimate. Fusion may be of one or multiple types including cross-modality fusion across different sensor types, within-modality fusion across different instances of same-type sensors, and cross-algorithm fusion using different algorithms for the same sensor(s).

Konrad, Janusz L.↗
DOE OSTI2024

Development of Readily Available & Robust High Heat Flux Gardon Gauges

Concentrated solar power (CSP) technologies deliver concentrated solar energy as a heat source to industrial processes, power generation cycles, and chemical cycles. CSP systems require accurate and reliable high flux measurements, and next generation CSP systems will require flux measurement up to 1000 W/cm2. Existing flux measurement devices do not comprehensively meet the flux rating, cycle life, cost, and lead-time needs of stakeholders, necessitating the development of an improved flux sensor. In this study, Sandia National Laboratories (SNL) partnered with Hukseflux Thermal Sensors to develop a low-cost, short lead-time, and robust flux sensor rated to 250 W/cm2. Three prototype circular foil gauge designs were assessed for performance at the National Solar Thermal Test Facility (NSTTF) at SNL. Each gauge design measured flux up to 250 W/cm2 with <5% measurement error. Following baseline error quantification, gauges were exposed to flux above 500 W/cm2 to assess gauge failure mechanisms. Gauges physically survived >500 W/cm2 flux exposure, but measurement error was found to increase after foil coatings reached 400 °C. The results of this study suggest that coating optical properties change at excessive temperatures and that foil coating temperature, rather than heat flux level, dictates the acceptable gauge measurement range.

McLaughlin, Luke (ORCID:0000000303711310)↗
DOE OSTI2020

One-Step Ahead Prediction of Thermal Mixing Tee Sensors with Long Short Term Memory (LSTM) Neural Networks

High-temperature advanced reactors under development, such as sodium fast reactors (SFR) and molten salt cooled reactors (MSCR), are expected to offer lower levelized cost of energy (LCOE) compared to existing light water reactor (LWR’s). In the existing light water reactors (LWR’s), operation and maintenance (O&M) expenses constitute the largest fraction of the total operating cost. Some of the O&M costs are related maintenance of sensors which can fail due to exposure to harsh environment in a reactor. The O&M costs of Advanced Reactor (AR)’s are expected to constitute a significant fraction of the total cost as well, because of high temperature and radiation level in AR are likely to cause material fatigue and premature failure of sensors and components. The O&M costs in AR’s could be reduced through integration of advanced informatics of performance-related sensors into a digital twin designed for reactor monitoring. For example, machine learning (ML) could be employed for real-time validation and correction of performance-related sensors, and reducing the number of performance-related physical sensor units through virtual sensing. As part of the effort, we investigate real-time validation of thermal hydraulic sensors through one-step ahead forecasting of sensor values using long short-term memory (LSTM) recurrent neural networks (RNN). The sensors are installed in a flow loop containing a thermal mixing tee, which is a common experimental model to study thermal fatigue in a thermal hydraulic loop. In addition, nonlinear transients generated in a thermal mixing tee constitute a good challenge data set for training and validation of ML algorithms. Sensors in this study include thermocouples, flow meters, and optical fibers for distributed temperature sensing. In one experiment, measurement data sets were obtained for a loop was filled with water, and in another experiment, measurements were performed on a loop filled with liquid metal Galinstan. We have also conducted preliminary investigation of one-step ahead prediction of fiber optics-based distributed temperature sensing with LSTM networks. In predicting fiber-based temperature measurements, we treated each gauge pitch of the fiber as an independent sensor. Accuracy of one-step ahead forecasting was estimated by calculating root mean square error (RMSE) for the test segment of time series of each sensor. RMSE’s for temperature sensors in water loop were, for the most part, lower than for the same sensors in Galinstan loop. The RMSE’s for flow meters were similar for both loops. The RMSE’s for distributed temperature measured with the fiber optic sensor were similar to those of the point sensors. Results of this study demonstrated the capability of LSTM one-step ahead forecasting with RMSE comparable to uncertainty in sensor measurements.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2026

Advancing Industry 4.0: Multimodal Sensor Fusion for AI-Based Fault Detection in 3D Printing

Additive manufacturing, particularly fused deposition modeling, is transforming modern production by enabling rapid prototyping and complex part fabrication. However, its layer-by-layer process remains vulnerable to faults such as nozzle clogging, filament runout, and layer misalignment, which compromise print quality and reliability. Traditional inspection methods are costly, time-intensive, and often limited to post-process analysis, making them unsuitable for real-time intervention. In this current study, the authors developed a novel, low-cost, and portable faultdetection system that leverages multimodal sensor fusion and artificial intelligence for real-time monitoring in FDM-based 3D printing. The system integrates acoustic, vibration, and thermal sensing into a non-intrusive architecture, capturing complementary data streams that reflect both mechanical and process-related anomalies. Acoustic and thermal sensors operate in a fully contactless manner, while the vibration sensor requires minimal attachment such that it will not interfere with printer hardware, thereby preserving portability and ease of deployment. The multimodal signals are processed into spectrograms and time-frequency features, which are classified using convolutional neural networks for intelligent fault detection. The proposed system advances Industry 4.0 objectives by offering an affordable, scalable, and practical monitoring solution that improves faultdetection accuracy, reduces waste, and supports sustainable, adaptive manufacturing.

42 ENGINEERING↗
DOE OSTI2022

Estimation of Corn Latent Heat Flux from High Resolution Thermal Imagery

Crop evapotranspiration (ET), which is directly related to latent heat flux, is also a key indicator in determining the water status of crops. In order to estimate the latent heat flux, two-source energy balance (TSEB) models have been developed for thermal imagery from satellite platforms. However, because of the coarse resolution of thermal sensors on the satellite, distinguishing soil and vegetation is difficult which complicates the calculation process and introduces errors in latent heat estimates. In this research, high-resolution thermal datasets (0.05 m) and corresponding RGB datasets (0.03 m) were used for calculating crop latent heat flux using an adapted TSEB model. The RGB datasets were used for supervised classification of soil and vegetation, and the classification results were then used to filter the thermal mosaics to separate vegetation and soil temperatures. The vegetation temperature is used for calculating latent heat flux and the results are validated against the ground reference measurements of latent heat using a handheld porometer. The objective of this research is to introduce a workflow including an adapted TSEB model which is customized for high resolution thermal images from unmanned aircraft systems (UAS) to estimate the latent heat flux of row crops in agricultural fields. Nine dates of data collection in 2018 and 2020 have been evaluated and the root mean square error (RMSE) varies between 16 to 106 W/m2 depending on the days after planting (DAP) and the time of measurement for each day. The results indicate that the workflow introduced here is able to provide estimates of instantaneous latent heat flux (evapotranspiration) measurements for row crops in agricultural fields which will enable people to make reliable decisions related to irrigation scheduling.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

Polymer-Based Thermally Stable Chemiresistive Sensor for Real-Time Monitoring of NO 2 Gas Emission

Here, we present a thermally stable, mechanically compliant, and sensitive polymer-based NO 2 gas sensor design. Interconnected nanoscale morphology driven from spinodal decomposition between conjugated polymers tethered with polar side chains and thermally stable matrix polymers offers judicious design of NO 2 -sensitive and thermally tolerant thin films. The resulting chemiresitive sensors exhibit stable NO 2 sensing even at 170 °C over 6 h. Controlling the density of polar side chains along conjugated polymer backbone enables optimal design for coupling high NO 2 sensitivity, selectivity, and thermal stability of polymer sensors. Lastly, thermally stable films are used to implement chemiresistive sensors onto flexible and heat-resistant substrates and demonstrate a reliable gas sensing response even after 500 bending cycles at 170 °C. Such unprecedented sensor performance as well as environmental stability are promising for real-time monitoring of gas emission from vehicles and industrial chemical processes.

47 OTHER INSTRUMENTATION↗
DOE OSTI2022

Evaluation of UAV-derived multimodal remote sensing data for biomass prediction and drought tolerance assessment in bioenergy sorghum

Screening for drought tolerance is critical to ensure high biomass production of bioenergy sorghum in arid or semi-arid environments. The bottleneck in drought tolerance selection is the challenge of accurately predicting biomass for a large number of genotypes. Although biomass prediction by low-altitude remote sensing has been widely investigated on various crops, the performance of the predictions are not consistent, especially when applied in a breeding context with hundreds of genotypes. In some cases, biomass prediction of a large group of genotypes benefited from multimodal remote sensing data; while in other cases, the benefits were not obvious. In this study, we evaluated the performance of single and multimodal data (thermal, RGB, and multispectral) derived from an unmanned aerial vehicle (UAV) for biomass prediction for drought tolerance assessments within a context of bioenergy sorghum breeding. The biomass of 360 sorghum genotypes grown under well-watered and water-stressed regimes was predicted with a series of UAV-derived canopy features, including canopy structure, spectral reflectance, and thermal radiation features. Biomass predictions using canopy features derived from the multimodal data showed comparable performance with the best results obtained with the single modal data with coefficients of determination (R 2 ) ranging from 0.40 to 0.53 under water-stressed environment and 0.11 to 0.35 under well-watered environment. The significance in biomass prediction was highest with multispectral followed by RGB and lowest with the thermal sensor. Finally, two well-recognized yield-based drought tolerance indices were calculated from ground truth biomass data and UAV predicted biomass, respectively. Results showed that the geometric mean productivity index outperformed the yield stability index in terms of the potential for reliable predictions by the remotely sensed data. Collectively, this study demonstrated a promising strategy for the use of different UAV-based imaging sensors to quantify yield-based drought tolerance.

09 BIOMASS FUELS↗
DOE OSTI2026

Surface and Buried Thermal, and RGB Unexploded Ordnance Data Collection

This document provides a description of a data collection campaign of unexploded ordnance (UXOI) set. The dataset captures a controlled UAV imaging campaign designed to support detection of UXO across varied environmental conditions. Data were collected during three campaigns in Norris and Northeast Knoxville, Tennessee, using RGB, and thermal sensors mounted on Parrot UKR. In total, the dataset contains 9925 images, 26 full-motion video, and approximately 81.99 GB of data, collected across late spring/summer conditions, every hour during sunlight, and multiple surface contexts, including tall grass, short grass, gravel, as well as buried in sand, and other gravel mixtures. The collection was designed to capture thermal and visual variability relevant to UXO detection in agricultural land, bare earth, and subsurface. Review of the imagery showed that ordnance was most detectable during periods of changing solar input, especially approximately 10-60 minutes after sunrise, approximately 20-60 minutes after sunset, and 2-3 min after cloud cover interrupted prolonged solar heating. These conditions increased thermal contrast because many ordnance items retained or released heat differently than the surrounding vegetation and ground surface. This dataset provides a useful resource for developing and evaluating airborne UXO detection methods under realistic field conditions. All ordnance used in the study was inert, and thermal behavior may differ from that of live ordnance. In addition, variation in ordnance type, composition, and placement introduced differences in thermal response that should be considered when interpreting results.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗
DOE OSTI2024

Daytime cooling efficiencies of urban trees derived from land surface temperature are much higher than those for air temperature

Accurately capturing the impact of urban trees on temperature can help optimize urban heat mitigation strategies. Recently, there has been widespread use of remotely sensed land surface temperature (T s ) to quantify the cooling efficiency (CE) of urban trees. However, remotely sensed T s reflects emitted radiation from the surface of an object seen from the point of view of the thermal sensor, which is not a good proxy for the air temperature (T a ) perceived by humans. The extent to which the CEs derived from T s reflect the true experiences of urban residents is debatable. Therefore, this study systematically compared the T s -based CE (CE T s ) with the T a -based CE (CE T a ) in 392 European urban clusters. CE T s and CE T a were defined as the reductions in T s and T a , respectively, for every 1% increase in fractional tree cover (FTC). The results show that the increase in FTC has a substantial impact on reducing T s and T a in most cities during daytime. However, at night, the response of T s and T a to increased FTC appears to be much weaker and ambiguous. On average, for European cities, daytime CE T s reaches 0.075 °C % -1 , which is significantly higher (by an order of magnitude) than the corresponding CE T a of 0.006 °C % -1 . In contrast, the average nighttime CE T s and CE T a for European cities are similar, both approximating zero. Overall, urban trees can lower daytime temperatures, but the magnitude of their cooling effect is notably amplified when using remotely sensed T s estimates compared to in situ T a measurements, which is important to consider for accurately constraining public health benefits. Our findings provide critical insights into the realistic efficiencies of alleviating urban heat through tree planting.

54 ENVIRONMENTAL SCIENCES↗