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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 253 records · Page 14
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

NanoPSD: A software for automatic detection of Nano-Particle Shape Distribution in electron microscopy images

Accurate quantification of the size and morphology of nanoparticles from electron microscopy (EM) images is essential to understand growth mechanisms, surface reactivity, and functional behavior in nanoscale materials. Manual analysis remains slow, subjective, and difficult to reproduce in large datasets. We introduce NanoPSD (Nano-Particle Shape Distribution), an open-source and fully automated framework for quantitative particle detection and morphology analysis from EM images. NanoPSD integrates adaptive contrast enhancement, polarity-agnostic scale-bar detection, Optical Character Recognition (OCR)-based calibration, and classical segmentation via Otsu thresholding with morphological refinement. Particle contours are used to extract geometric descriptors, including equivalent circular diameter, aspect ratio, circularity, and solidity, enabling automated classification into spherical, rod-like, and aggregate morphologies. The framework supports both single-image and batch processing, generating publication-quality visualizations, LaTeX-ready tables, and structured comma-separated values (CSV) datasets. As a demonstration, we applied NanoPSD to plasma-synthesized nanoparticle samples diagnosed via transmission electron microscopy (TEM). The code produced statistically robust size and morphology distributions spanning a few to tens of nanometers with minimal user supervision. The pipeline demonstrates high reproducibility and scalability, processing large image collections with consistent calibration and output formatting. Its modular design enables seamless integration of future deep-learning-based segmentation models, providing a pathway toward intelligent, data-driven electron microscopy analysis.

36 MATERIALS SCIENCE↗
DOE OSTI2026

ClassNMSW- a real-time classification approach for non-recycled municipal solid waste using hyperspectral imaging

Real-time classification of non-recycled municipal solid waste (NMSW) is essential for efficient valorization. This study introduces ClassNMSW, a comprehensive framework for classifying 22 NMSW subclasses under industrial constraints by using hyperspectral imaging (HSI). A primary innovation of this work is the development of a variance-controlled spectral extraction algorithm. Unlike traditional methods that rely on simple averaging, this approach systematically investigates the extent of pixel extraction to minimize the loss of critical chemical information while maximizing data reduction thus ensuring high spectral fidelity with low computational cost. The approach developed in this work integrates automated, computer-vision-based background removal, eliminating the need for the manual thresholding common in current literature. To resolve ambiguities among chemically similar subclasses, a tiered classification and multi-camera fusion strategy (NIR17 and NIR22) is implemented. Results demonstrate that ClassNMSW achieves an object-wise weighted accuracy of 98.70% for single-sensor configurations and 100% under sensor fusion. A novel rolling-window strategy satisfies desired end-to-end latency of <2 s, satisfying the strict deterministic requirements of high-speed industrial sorting environments. The ClassNMSW framework provides a scalable foundation for advancing circularity and resource recovery in large-scale waste valorization operations.

99 - GENERAL AND MISCELLANEOUS↗
DOE OSTI2020

Deep Learning for Intelligent Bubble Size Detection in the Spallation Neutron Source Visual Target

The Spallation Neutron Source (SNS) at Oak Ridge National Laboratory (ORNL) will undergo proton power upgrade (PPU), increasing the proton beam power from 1.4 MW to 2.8 MW. From 2.8 MW, 2.0 MW will go to the current First Target Station and the rest will go to the future Second Target Station (STS). The First Target Station uses a liquid mercury target that is contained in a 316L stainless steel vessel. The proton beam is pulsed at 60 Hz, with a pulse of about 0.7μs. When the proton beam hits the target, the intense energy deposition leads to a rapid rise in temperature in the mercury. This temperature rise creates pressure waves that propagate through the mercury and cause cavitation erosion. The power upgrade will cause stronger pressure waves that will further increase damage because of cavitation. Injecting small helium bubbles in the mercury has been an efficient method of mitigating the pressure wave at 1.4 MW. However, at higher power, additional mitigation is necessary. Therefore, the 2 MW target vessel will be equipped with swirl bubblers and an additional gas injection port near the nose to inject more gas in the target. To develop a gas injection strategy and design, flow visualization in water with a transparent prototypical target (“visual target”) was performed. Bubble sizes and their spatial distribution in the flow loop are crucial to understanding the effectiveness of the bubbles in mitigating pressure waves. Bubbles were generated in the visual target under varied conditions of input pressures with helium and air. Images were captured using a high-speed camera at varied frame rates at different positions away from the swirl bubbler and different depths in the flow loop under varying lighting conditions. Initially, methods such as circular Hough transforms were applied after a series of images processing to obtain a general distribution of bubble sizes. Bubbles smaller than 500 μm are preferred to effectively mitigate the effect of pressure waves, which demands an accurate bubble detection and sizing system. Intelligent detection and identification of bubble sizes alleviate misdetection and improves accuracies. Employing neural networks, intelligent detection of bubble sizes and their distribution was developed and provides a robust alternative to traditional techniques. Human intervention was employed to label in-focus and out-of-focus bubbles in the set of training images. An object detection network using a pretrained convolutional neural network was created that extracted the features from the training images. Data augmentation was used to improve network accuracy through a random transformation of the original data.

Rasheed, Fayaz↗
DOE OSTI2024

Multiscale modeling of HBV infection integrating intra- and intercellular viral propagation to analyze extracellular viral markers

Chronic infection with hepatitis B virus (HBV) is caused by the persistence of closed circular DNA (cccDNA) in the nucleus of infected hepatocytes. Despite available therapeutic anti-HBV agents, eliminating the cccDNA remains challenging. Thus, quantifying and understanding the dynamics of cccDNA are essential for developing effective treatment strategies and new drugs. However, such study requires repeated liver biopsy to measure the intrahepatic cccDNA, which is basically not accepted because liver biopsy is potentially morbid and not common during hepatitis B treatment. We here aimed to develop a noninvasive method for quantifying cccDNA in the liver using surrogate markers in peripheral blood. We constructed a multiscale mathematical model that explicitly incorporates both intracellular and intercellular HBV infection processes. The model, based on age-structured partial differential equations, integrates experimental data from in vitro and in vivo investigations. By applying this model, we roughly predicted the amount and dynamics of intrahepatic cccDNA within a certain range using specific viral markers in serum samples, including HBV DNA, HBsAg, HBeAg, and HBcrAg. Our study represents a significant step towards advancing the understanding of chronic HBV infection. The noninvasive quantification of cccDNA using our proposed method holds promise for improving clinical analyses and treatment strategies. By comprehensively describing the interactions of all components involved in HBV infection, our multiscale mathematical model provides a valuable framework for further research and the development of targeted interventions.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2026

Errors in reconstruction of dichroic X-ray orientation tomography due to polarization rotation of the incident beam

Dichroic X-ray tomography is a technique in which the crystal orientation or magnetization of a sample is resolved in three dimensions. The best-known uses of this technique are for observation of magnetic moments via circular dichroism, using left- and right-handed circularly polarized X-ray beams. Another variant uses linear dichroism to resolve the crystal orientation. In both these techniques, it is assumed that the absorption of X-rays along a path inside a material can be computed as a line integral of a local absorption coefficient along the ray path. For linear dichroism, this assumption is inaccurate because the polarization of the beam changes along the propagation direction when the optic axis of the material is not aligned along the polarization. In this work, a finite-element Maxwell solver is used to simulate tomography and reconstructions. The propagation effect can lead to significant errors in the reconstructed orientations. These errors may be mitigated by taking data at additional angles or by operating at energies at which the dichroism is weak. An iterative approach is proposed which may allow accurate reconstruction with fewer data than would otherwise be required.

X-ray linear dichroism↗
DOE OSTI2022

American Made Challenges Battery Voucher Program Cooperative Research and Development Agreement (Cooperative Research and Development Final Report, CRADA Number CRD-21-17533)

Renewance is a Phase II winner of the U.S. Department of Energy Lithium-ion Battery Recycling Prize. The Prize is designed to incentivize American entrepreneurs to develop and demonstrate processes that, when scaled, have the potential to profitably capture 90% of all discarded or spent lithium-based batteries (LIB) in the Unites States for eventual recovery of key materials for re-introductions into the U.S. supply chain. The objective of this work is to enable a more efficient evaluation of battery sources for second life applications prior to ultimately being recycled, through evaluation of chemistry characteristics, projected battery lifetime, and application history. This work will develop the capability to identify groups of batteries that may be useful for second life and reduce the cost of end-of-life (EOL) LIB evaluation and repurposing. To meet the objective, NREL will use existing and new data to create a refined algorithm that could be used to evaluate batches of batteries for potential reuse based on manufacturing date and historical use characteristics. Based on current battery market prices and compiled literature data, a starting-point estimate of the market value of the batteries for reuse based on expected lifetime will be included in the algorithm. With the projected surge in LIB demand, battery second life is a new area ripe for development and investment from companies like Renewance. With so few large format batteries reaching EOL to date, this is a new market with a variety of areas for optimization and adding value. This work with Renewance is an example of how existing expertise in battery degradation at NREL can be used to reduce the cost of shifting a battery into a second life application. With these cost reductions, this work is also facilitating the development of a battery circular economy in the United States. A robust circular economy can maximize the utilization of critical metals demanded by battery technology such as nickel and cobalt while also reducing the costs of batteries in the marketplace for the many end-uses needed for the green energy transition. The supply of these metals is limited, and we face a supply chain shortage both domestically and globally unless we can ensure they are being used to their maximum potential. This research can improve the economics of a battery circular economy to make it a more likely path for EOL batteries with critical metals. CRADA benefit to DOE, Participant, and US Taxpayer: assists laboratory in achieving programmatic scope competencies, uses the laboratory's core competencies.

25 ENERGY STORAGE↗
DOE OSTI2020

Structure of the Diphtheria Toxin at Acidic pH: Implications for the Conformational Switching of the Translocation Domain

Diphtheria toxin, an exotoxin secreted by Corynebacterium that causes disease in humans by inhibiting protein synthesis, enters the cell via receptor-mediated endocytosis. The subsequent endosomal acidification triggers a series of conformational changes, resulting in the refolding and membrane insertion of the translocation (T-)domain and ultimately leading to the translocation of the catalytic domain into the cytoplasm. Here, we use X-ray crystallography along with circular dichroism and fluorescence spectroscopy to gain insight into the mechanism of the early stages of pH-dependent conformational transition. For the first time, we present the high-resolution structure of the diphtheria toxin at a mildly acidic pH (5–6) and compare it to the structure at neutral pH (7). We demonstrate that neither catalytic nor receptor-binding domains change their structure upon this acidification, while the T-domain undergoes a conformational change that results in the unfolding of the TH2–3 helices. Surprisingly, the TH1 helix maintains its conformation in the crystal of the full-length toxin even at pH 5. This contrasts with the evidence from the new and previously published data, obtained by spectroscopic measurements and molecular dynamics computer simulations, which indicate the refolding of TH1 upon the acidification of the isolated T-domain. The overall results imply that the membrane interactions of the T-domain are critical in ensuring the proper conformational changes required for the preparation of the diphtheria toxin for the cellular entry.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2024

The Escape Velocity Profile of the Milky Way from Gaia DR3

Abstract The escape velocity profile of the Milky Way offers a crucial and independent measurement of its underlying mass distribution and dark matter (DM) properties. Using a sample of stars from the third data release of Gaia with 6D kinematics and strict quality cuts, we obtain an escape velocity profile of the Milky Way from 4 to 11 kpc in Galactocentric radius. To infer the escape velocity in radial bins, we model the tail of the stellar speed distribution with both traditional power-law models and a new functional form that we introduce. While power-law models tend to rely on extrapolation to high speeds, we find our new functional form gives the most faithful representation of the observed distribution. Using this for the escape velocity profile, we constrain the properties of the Milky Way’s DM halo modeled as a Navarro–Frenck–White profile. Combined with constraints from the circular velocity at the solar position, we obtain a concentration and mass of c 200 c DM = 13.9 − 4.3 + 6.2 and M 200 c DM = 0.55 − 0.14 + 0.15 × 10 12 M ⊙ . This corresponds to a total Milky Way mass of M 200 c = 0.64 − 0.14 + 0.15 × 10 12 M ⊙ , which is on the low end of the historic range of the galaxy’s mass, but in line with other recent estimates.

Astronomy & Astrophysics↗
DOE OSTI2024

Investigation of the notch sensitivity of tailorable long fiber discontinuous prepreg composite laminates

Tailorable discontinuous fiber composite laminates provide relative formability beyond that of continuous fiber laminates, while achieving improved mechanical performance over comparable stochastic systems. Here, in this work, the notch sensitivity of engineered prepreg platelet molded composite (PPMC) laminates is investigated using the open-hole tension (OHT) test and compared to available data for stochastic PPMCs and continuous fiber laminates made with the same material. The press-formed thermoplastic composites (AS4/PEKK) were molded with a quasi-isotropic stacking sequence. The discontinuous PPMC laminate was found to be notch insensitive with OHT strengths ranging from 145.4 MPa (CV $=$ 7%) for d/w $=$ 0.5 to 229.3 MPa (CV $=$ 9%) for d/w $=$ 0.25. The highly ordered meso-structure of the engineered PPMC laminate yields comparatively excellent mechanical properties for relatively thin laminates in contrast to stochastic systems. Both net- and gross-section failures were observed for d/w $=$ 0.25, which suggests that the engineered PPMC laminates studied here maintain a degree of inherent, internal stress concentrations that compete with those caused by geometric features such as a circular hole. Computational simulations of the OHT tests with explicitly represented platelets were found to be in good agreement with experimental measurements. The progressive failure analysis was used to conduct a numerical investigation of the stacking sequence and platelet meso-morphology.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Computational Evaluation of Thermal Response of Open-Cell Foam With Circular Pore (Computional Evaluation of Thermal Response of Open-Cell Foam with Circular Pore)

The evaluation of effective material properties in heterogeneous materials (e.g., composites or multicomponent structures) critically relevant to a wide spectrum of applications, including nuclear power, electronic packaging, flame retardants, hypersonics, and gas turbine power. The work described in this paper is centered around the numerical assessment of the thermal behavior of porous materials obtained from finite element thermal modeling and simulation. Here, two-dimensional, steady state analyses were performed on unit cells with centered, circular pores using a second order accurate Galerkin finite element method (FEM). The effective thermal conductivities of the porous systems were examined, encompassing a range of porosities from 4.9% to 60.1%. The geometries of the models were generated based on ordered circular pores for each modeled porosity level. The system response quantity (SRQ) under investigation was the dimensionless effective thermal conductivity across the unit cell. The dimensionless effective thermal conductivity was compared across all simulated cases, producing a trend between porosity and effective thermal conductivity. In the presented investigation, the method of manufactured solutions (MMS) was used to perform code verification, and the grid convergence index (GCI) was employed to estimate discretization uncertainty as solution verification. Code verification concluded an approximately second order accurate Galerkin FEM solver. It was found that the introduction of porosity to the unit cell material structure reduces effective thermal conductivity, as anticipated. Numerical results obtained in this study are compared to an analytical solution and to a sample of empirical data.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Two Bright M Dwarfs Hosting Ultra-Short-Period Super-Earths with Earth-like Compositions

We present observations of two bright M dwarfs (TOI-1634 and TOI-1685: J = 9.5–9.6) hosting ultra-short-period (USP) planets identified by the TESS mission. The two stars are similar in temperature, mass, and radius (T {sub eff} ≈ 3500 K, M {sub &middot;} ≈ 0.45–0.46 M {sub ⊙}, and R {sub &middot;} ≈ 0.45–0.46 R {sub ⊙}), and the planets are both super-Earth size (1.25 R {sub ⊕} < R {sub p} < 2.0 R {sub ⊕}). For both systems, light curves from ground-based photometry exhibit planetary transits, whose depths are consistent with those from the TESS photometry. We also refine the transit ephemerides based on the ground-based photometry, finding the orbital periods of P = 0.9893436 ± 0.0000020 days and P = 0.6691416 ± 0.0000019 days for TOI-1634b and TOI-1685b, respectively. Through intensive radial velocity (RV) observations using the InfraRed Doppler (IRD) instrument on the Subaru 8.2 m telescope, we confirm the planetary nature of the TOIs and measure their masses: 10.14 ± 0.95 M {sub ⊕} and 3.43 ± 0.93 M {sub ⊕} for TOI-1634b and TOI-1685b, respectively, when the observed RVs are fitted with a single-planet circular-orbit model. Combining those with the planet radii of R {sub p} = 1.749 ± 0.079 R {sub ⊕} (TOI-1634b) and 1.459 ± 0.065 R {sub ⊕} (TOI-1685b), we find that both USP planets have mean densities consistent with an Earth-like internal composition, which is typical for small USP planets. TOI-1634b is currently the most massive USP planet in this category, and it resides near the radius valley, which makes it a benchmark planet in the context of discussing the size limit of rocky planet cores as well as testing the formation scenarios for USP planets. Excess scatter in the RV residuals for TOI-1685 suggests the presence of a possible secondary planet or unknown activity/instrumental noise in the RV data, but further observations are required to check those possibilities.

47 OTHER INSTRUMENTATION↗
DOE OSTI2023

Several Small or Single Large? Quantifying the Catchment-Wide Performance of On-Site Wastewater Treatment Plants with Inaccurate Sensors

On-site wastewater treatment plants (OSTs) often lack monitoring, resulting in unreliable treatment performance. They thus appear to be a stopgap solution despite their potential contribution to circular water management. Low-maintenance but inaccurate soft sensors are emerging that address this concern. However, how their inaccuracy impacts the catchment-wide treatment performance of a system of many OSTs has not been quantified. Here, we develop a stochastic model to estimate catchment-wide OST performances with a Monte Carlo simulation. In our study, soft sensors with a 70% accuracy improved the treatment performance from 66% of the time functional to 98%. Soft sensors optimized for specificity, indicating the true negative rate, improve the system performance, while sensors optimized for sensitivity, indicating the true positive rate, quantify the treatment performance more accurately. This new insight leads us to suggest programming two soft sensors in practical settings with the same hardware sensor data as input: one soft sensor geared to high specificity for maintenance scheduling and one geared to high sensitivity for performance quantification. Our findings suggest that a maintenance strategy combining inaccurate sensors with appropriate alarm management can vastly improve the mean catchment-wide treatment performance of a system of OSTs.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Breakdown characteristics of deep-ultraviolet Al 0.6 Ga 0.4 N p-i-n avalanche photodiodes

A top-illuminated deep-ultraviolet Al 0.6 Ga 0.4 N p-i-n avalanche photodiode (APD) structure was designed and grown by metalorganic chemical vapor deposition on an AlN bulk substrate and on two different quality AlN/sapphire templates, and APDs were fabricated and tested. The APD devices with a circular diameter of 20 μm have demonstrated a distinctive reverse-bias breakdown behavior. The reverse breakdown voltage of the APDs is approximately -140 V, which corresponds to a breakdown electric field of 6–6.2 MV/cm for the Al 0.6 Ga 0.4 N material as estimated by Silvaco TCAD simulation. The APDs grown on the AlN bulk substrate show the lowest leakage current density of < 1 × 10 -8 A/cm 2 (at low reverse bias) compared to that of the devices grown on the AlN templates. From the photocurrent measurement, a maximum gain (current limited) of 1.2 × 10 4 is calculated. The average temperature coefficients of the breakdown voltage are negative for APD devices fabricated from both the AlN bulk substrate and the AlN templates, but these data show that the coefficient is the least negative for the APD devices grown on the low-dislocation-density AlN bulk substrate.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2022

Interim Report on FY22 ORNL A709 Welding Research and Testing of Production Welds in Support of Developing ASME A709 Code Case Data Package

As part of the Alloy 709 ASME Code Case development effort under the Advanced Reactor Technologies (ART) Program, this work covers the development of the technical basis for weld fabrication and weld qualification of Alloy 709. This report summarizes the Alloy 709 welding research conducted at Oak Ridge National Laboratory (ORNL) in FY 2022. Two new production welds were fabricated on two commercial heats of Alloy 709 of different phosphorus (P) levels using Alloy 709 filler metal with P content less than 20 wppm with gas tungsten arc welding (GTAW). Both production welds successfully passed ASME Section IX weld qualification tests, and this concludes the Alloy 709 welding procedure development to scale up to 2-in thick plates. In FY 2022, we also demonstrated the success in welding of high P commercial Alloy 709 plates with weld wires having higher P content at 30 wppm. A test weld fabricated with the 30 wppm weld wire on the first commercial heat (140 wppm P) passed all weld qualification tests without issues. Additionally, experiment setup and testing procedure of the circular patch weldability test has been developed, for evaluating the P effect in weld wire on solidification cracking susceptibility of Alloy 709 weld, with the preliminary results summarized in this report. Research on further relaxing the P level restriction beyond 30 wppm are planned in FY 2023. The preliminary cross-weld creep tests results continue to show little or no creep strength reduction relative to the base metal.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Once in a blue stream: Detection of recent star formation in the NGC 7241 stellar stream with MEGARA

Aims.In this work we study the striking case of a narrow blue stream with a possible globular cluster-like progenitor around the NGC 7241 galaxy and its foreground dwarf companion. We want to figure out if the stream was generated by tidal interaction with NGC 7241 or if it first interacted with the foreground dwarf companion and later both fell together toward NGC 7241. Methods.We used four sets of observations, including a follow-up spectroscopic study of this stream based on data taken with the MEGARA instrument at the 10.4 m Gran Telescopio Canarias using the integral field spectroscopy mode, the Mount Lemmon 0.80 m telescope, the Telescopio NazionaleGalileo, the DESI Imaging Legacy surveys, and GALEX archival data. We also used high-resolution zoomed-in cosmological simulations. Results.Our data suggest that the compact object we detected in the stream is a foreground Milky Way halo star. Near this compact object we detect emission lines overlapping a less compact, bluer, and fainter blob of the stream that is clearly visible in both ultraviolet and optical deep images. From its heliocentric systemic radial velocity derived from the [O III]λ5007 Å lines (V syst = 1548.58 ± 1.80 km s −1 ) and new UV and optical broadband photometry, we conclude that this overdensity could be the actual core of the stream, with an absolute magnitude ofM g ∼ −10 and ag − r = 0.08 ± 0.11, consistent with a remnant of a low-mass dwarf satellite undergoing a current episode of star formation. From the width of the stream and assuming a circular orbit, we calculate that the progenitor mass can be typical of a dwarf galaxy, but it could also be substantially lower if the stream is on a very radial orbit or if it was created by tidal interaction with the companion dwarf instead of with NGC 7241. These estimates also suggest that this is one of the lowest mass streams detected to date beyond the Local Group. Finally, we find that blue stellar streams containing star formation regions are commonly predicted by high-resolution cosmological simulations of galaxies lighter than the Milky Way. This scenario is consistent with the processes explaining the bursty star formation history of some dwarf satellites, which are followed by a gas depletion and a fast quenching once they enter within the virial radius of their host galaxies for the first time. Thus, it is likely that the stream’s progenitor is undergoing a star formation burst comparable to those that have shaped the star formation history of several Local Group dwarfs in the last few gigayears.

Astronomy & Astrophysics↗
DOE OSTI2021

Network Based Estimation of Wind Farm Power and Velocity Data Under Changing Wind Direction

This paper describes an estimation algorithm for velocity and power output signals in a wind farm under changing wind direction. A graph-theoretic definition describes the wind farm as a collection of nodes (turbines) and time-varying weighted edges (inter-turbine wake propagation) that change as a function of incoming wind direction. The velocity at each turbine is determined through a discrete input-output model. Changes in wind direction serve as the input and the output is defined in terms of a time-varying weighted adjacency matrix that depends on the time-delay of information propagation between turbines. These delays, which are defined in terms of the advection speed of the wind and the distance between the turbines, capture the delayed effect of wind direction changes on the inter-connectivity of the graph as the wind conditions at the farm inlet propagate through the turbine array. An event-based update framework is employed to capture time-dependent topology changes due to shifts in wind direction. Simulation results for dynamically changing wind inlet directions to a circular wind farm are compared to predictions from both the static and dynamic versions of the FLOw Redirection and Induction in Steady State (FLORIS) model. The approach is shown to enable real-time tracking of dynamic changes to wind farm power output within a framework that can be easily integrated into real-time, horizon-based, control strategies that typically do not account for wind direction changes.

distributed↗
DOE OSTI2021

Development of NDE/NDT Tools for High-Volume & High-Speed Inspection of CFRP Structures in Automotive Manufacturing

Main advantages of the air-coupled ultrasound testing (ACUT) and electromagnetic testing (EMT) techniques for NDE of CFRP composites were non-contact sensing, scalability for high-speed inspection, cost-effectiveness, and non-hazardous operation. Despite these advantages, no systems that would satisfy the project requirements were commercially available. Hence, one of the major efforts of the Michigan State University (MSU) team at the initial stage of the project was to close this technological gap by developing, optimizing, and validating array sensors that would provide sufficient sensitivity, spatial coverage, and resolution for robust defect detection. Optimization of the ACUT and EMT sensor designs was performed using experimentally validated finite element models. Initial experiments using array probes were conducted on relatively flat CFRP samples. In parallel, the MSU team designed and assembled a portable platform with two robotic arms. The robots were equipped with newly designed sensors that enabled high-speed NDE of curved CFRP parts. Presently, the developed robotic platform can be used as a demo/template NDE system, which is easily adaptable to manufacturing environments and in-line NDE. The ACUT NDE system developed by the MSU team used a high-power 4-channel pulser receiver for parallel data acquisition. The array probes were designed by stacking commercially available ACUT transducers, which operated in the frequency range between 100 kHz and 500 kHz. MSU optimized the excitation procedure and developed wave focusing cones so as to reduce the crosstalk between the transducers and to provide higher pulse repletion frequency (PRF). The through-transmission (TT) and single-side access (SSA) inspection modes were successfully implemented. In the TT-ACUT, structural defects in CFRP were detected by passing ultrasonic waves through the test part. Hence, the ACUT transmitters and receivers needed to be placed on the opposite sides of the test part. In the SSA-ACUT, guided waves (GW) were excited in the test part using the transmitters and were sensed by the receivers from the same side. Multi-channel TT-ACUT and SSA-ACUT provided high-speed NDE, and were successfully validated on CFRP test samples with interlaminar delaminations and other embedded defects The EM techniques developed by the MSU team included: 1) eddy current testing (ECT), 2) capacitive imaging (CI) and hybrid dual-mode imaging. In ECT, structural damage was detected in CFRP using coils sensor arrays. In ECT, the excitation magnetic field is generated by passing an alternating current through a coil, which is placed above the test sample. The excitation field penetrates the conductive sample and induces the eddy currents in its transect. In turn, the eddy currents generate the reaction field, which affects the total field sensed by a coil. Hence, the presence of structural flaws will alter the eddy current flow and the picked-up signal. ECT is mostly sensitive to local changes of the electric conductivity of the test sample, and CFRPs are mostly conductive in the direction of carbon fibers. Hence, ECT was well suited for the detection of fiber damage/fiber irregularities. The MSU team developed printed circuit boards (PCB) with coil sensor arrays optimized for NDE of CFRP. Unlike most commercial probes designed for ECT of metallic structures, the MSU array probes were designed for operation in [1-10] MHz frequency range, which was optimal for low-conductive CFRP. Multiple sensing topologies (coil groups excitation/sensing arrangements) were implemented and successfully validated. Capacitive Imaging (CI) technique developed by MSU was complementary to ECT. In contrast to ECT, which was sensitive to local changes of the electrical conductivity, the CI was sensitive to local changes of the dielectric constant. Therefore, CI could provide information about matrix damage/matrix irregularities in CFRP. The MSU CI sensor arrays were made of multiple circular or rectangular open-plate capacitors printed on PCB. Sensors of this type are not commercially available. In addition to ECT and CI, the MSU team developed a hybrid (dual-mode) inductive/capacitive measurement technique that synergistically combined the benefits of inductive and capacitive sensing for rapid NDE of fiber reinforced polymer (FRP) composite structures. Fiber damage and fiber irregularities in FRPs were detected by configuring hybrid sensors as coil sensors. Similarly, matrix damage, matrix irregularities and interlaminar delaminations were detected by configuring hybrid sensors as capacitive sensors. ECT and CI were performed sequentially by means of electronic switching. Hence, eliminating the need for mounting two separate sensor arrays on the probe. Portable robotic platform was developed by MSU for multi-technique high-speed NDE of CFRP test parts. The platform had two 6-axis robots, which enabled inspection of curved parts in approximately a 6×6×6 ft 3 active scan area. On the software side, the MSU team integrated scripts for NDE hardware control with scripts for robot motion control. MSU also implemented automated path planning for the robots, reconstruction of part’s surfaces via stereovision, 3D rendering of inspection data, and image processing algorithms for enhanced defect detection. Automotive composite parts manufactured by Plasan Composites from Phase I were used to validate the ACUT and EMT techniques on representative testbeds. Among those parts were three X-braces for a Dodge Viper, one composite calibration plaque with known defects at known locations, and four other test sections, including sections from a front splitter, a corner section from a composite hood, and a high-pressure RTM panel made using non crimp fabric. Other test samples included CFRP and GFRP calibration plates with fiber/matrix defects fabricated at MSU/CVRC.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Stellar Radial Velocities in the Old Open Cluster M67 (NGC 2682). II. The Spectroscopic Binary Population

We present and analyze 120 spectroscopic binary and triple cluster members of the old (4 Gyr) open cluster M67 (NGC 2682). As a cornerstone of stellar astrophysics, M67 is a key cluster in the WIYN Open Cluster Study (WOCS); radial-velocity (RV) observations of M67 are ongoing and extend back over 45 yr, incorporating data from seven different telescopes, and allowing us to detect binaries with orbital periods ≲10{sup 4} days. Our sample contains 1296 stars (604 cluster members) with magnitudes of 10 ≤ V ≤ 16.5 (about 1.3–0.7 M {sub ⊙}), from the giants down to ∼4 mag below the main-sequence turnoff, and extends in radius to 30′ (7.4 pc at a distance of 850 pc, or ∼7 core radii). This paper focuses primarily on the main-sequence binaries, but orbital solutions are also presented for red giants, yellow giants, and sub-subgiants. Out to our period detection limit and within our magnitude and spatial domain, we find a global main-sequence incompleteness-corrected binary fraction of 34% ± 3%, which rises to 70% ± 17% in the cluster center. We derive a tidal circularization period of P{sub circ}=11.0{sub −1.0}{sup +1.1} days. We also analyze the incompleteness-corrected distributions of binary orbital elements and masses. The period distribution rises toward longer periods. The eccentricity distribution, beyond P {sub circ}, is consistent with a uniform distribution. The mass-ratio distribution is also consistent with a uniform distribution. Overall, these M67 binaries are closely consistent with similar binaries in the galactic field, as well as with the old (7 Gyr) open cluster NGC 188. WOCS. 83.

47 OTHER INSTRUMENTATION↗