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DOE OSTI2016

Development and testing of an electrochemical methane sensor

In this article, the development of an electrochemical methane sensor is presented. The mixed potential based sensor is based on tin doped indium oxide (ITO) and platinum electrodes and yttria-stabilized zirconia (YSZ) electrolyte. The sensor was fabricated using the inexpensive tape-cast method. The sensor responded to methane with a response time of 15 s. The staircase response to methane indicated a 44 mV sensor response to 100 ppm of methane. The sensor response indicated a log-linear relationship with the methane concentration. Upon 500 h of sensor testing, a 5% reduction in methane sensitivity was observed. The cross-sensitivity study on the sensor indicated minimal interference to NO, NO 2 , and CO 2 . To improve the sensitivity to methane, a signal conditioning method referred to as the pulsed discharge technique (PDT) was applied. Finally, a fourfold increase in methane sensitivity was observed when the sensor was subjected to PDT. Future studies include the miniaturization of the sensor with integrated heater design.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

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 OSTI2015

SU-E-T-258: Development of a New Patient Set-Up Monitoring System Using Force Sensing Resistor (FSR) Sensor for the Radiation Therapy

Purpose: The purpose of this work is to develop a new patient set-up monitoring system using force sensing resistor (FSR) sensors that can confirm pressure of contact surface and evaluate its feasibility. Methods: In this study, we focused on develop the patient set-up monitoring system to compensate for the limitation of existing optical based monitoring system, so the developed system can inform motion in the radiation therapy. The set-up monitoring system was designed consisting of sensor units (FSR sensor), signal conditioning devices (USB cable/interface electronics), a control PC, and a developed analysis software. The sensor unit was made by attaching FSR sensor and dispersing pressure sponge to prevent error which is caused by concentrating specific point. Measured signal from the FSR sensor was sampled to arduino mega 2560 microcontroller, transferred to control PC by using serial communication. The measured data went through normalization process. The normalized data was displayed through the developed graphic user interface (GUI) software. The software was designed to display a single sensor unit intensity (maximum 16 sensors) and display 2D pressure distribution (using 16 sensors) according to the purpose. Results: Changes of pressure value according to motion was confirmed by the developed set-up monitoring system. Very small movement such as little physical change in appearance can be confirmed using a single unit and using 2D pressure distribution. Also, the set-up monitoring system can observe in real time. Conclusion: In this study, we developed the new set-up monitoring system using FSR sensor. Especially, we expect that the new set-up monitoring system is suitable for motion monitoring of blind area that is hard to confirm existing optical system and compensate existing optical based monitoring system. As a further study, an integrated system will be constructed through correlation of existing optical monitoring system. This work was supported by the Industrial R&D program of MOTIE/KEIT. [10048997, Development of the core technology for integrated therapy devices based on real-time MRI guided tumor tracking] and the Mid-career Researcher Program (2014R1A2A1A10050270) through the National Research Foundation of Korea funded by the Ministry of Science, ICT&Future Planning.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2024

Microbial sensor variation across biogeochemical conditions in the terrestrial deep subsurface

ABSTRACT Microbes can be found in abundance many kilometers underground. While microbial metabolic capabilities have been examined across different geochemical settings, it remains unclear how changes in subsurface niches affect microbial needs to sense and respond to their environment. To address this question, we examined how microbial extracellular sensor systems vary with environmental conditions across metagenomes at different Deep Mine Microbial Observatory (DeMMO) subsurface sites. Because two-component systems (TCSs) directly sense extracellular conditions and convert this information into intracellular biochemical responses, we expected that this sensor family would vary across isolated oligotrophic subterranean environments that differ in abiotic and biotic conditions. TCSs were found at all six subsurface sites, the service water control, and the surface site, with an average of 0.88 sensor histidine kinases (HKs) per 100 genes across all sites. Abundance was greater in subsurface fracture fluids compared with surface-derived fluids, and candidate phyla radiation (CPR) bacteria presented the lowest HK frequencies. Measures of microbial diversity, such as the Shannon diversity index, revealed that HK abundance is inversely correlated with microbial diversity ( r 2 = 0.81). Among the geochemical parameters measured, HK frequency correlated most strongly with variance in dissolved organic carbon ( r 2 = 0.82). Taken together, these results implicate the abiotic and biotic properties of an ecological niche as drivers of sensor needs, and they suggest that microbes in environments with large fluctuations in organic nutrients (e.g., lacustrine, terrestrial, and coastal ecosystems) may require greater TCS diversity than ecosystems with low nutrients (e.g., open ocean). IMPORTANCE The ability to detect extracellular environmental conditions is a fundamental property of all life forms. Because microbial two-component sensor systems convert information about extracellular conditions into biochemical information that controls their behaviors, we evaluated how two-component sensor systems evolved within the deep Earth across multiple sites where abiotic and biotic properties vary. We show that these sensor systems remain abundant in microbial consortia at all subterranean sampling sites and observe correlations between sensor system abundances and abiotic (dissolved organic carbon variation) and biotic (consortia diversity) properties. These results suggest that multiple environmental properties may drive sensor protein evolution and highlight the need for further studies of metagenomic and geochemical data in parallel to understand the drivers of microbial sensor evolution.

response regulator↗

DOE OSTI2012

Leak Detection and H2 Sensor Development for Hydrogen Applications

The objectives of this report are: (1) Develop a low cost, low power, durable, and reliable hydrogen safety sensor for a wide range of vehicle and infrastructure applications; (2) Continually advance test prototypes guided by materials selection, sensor design, electrochemical R&D investigation, fabrication, and rigorous life testing; (3) Disseminate packaged sensor prototypes and control systems to DOE Laboratories and commercial parties interested in testing and fielding advanced prototypes for cross-validation; (4) Evaluate manufacturing approaches for commercialization; and (5) Engage an industrial partner and execute technology transfer. Recent developments in the search for sustainable and renewable energy coupled with the advancements in fuel cell powered vehicles (FCVs) have augmented the demand for hydrogen safety sensors. There are several sensor technologies that have been developed to detect hydrogen, including deployed systems to detect leaks in manned space systems and hydrogen safety sensors for laboratory and industrial usage. Among the several sensing methods electrochemical devices that utilize high temperature-based ceramic electrolytes are largely unaffected by changes in humidity and are more resilient to electrode or electrolyte poisoning. The desired sensing technique should meet a detection threshold of 1% (10,000 ppm) H 2 and response time of {approx_equal}1 min, which is a target for infrastructure and vehicular uses. Further, a review of electrochemical hydrogen sensors by Korotcenkov et.al and the report by Glass et.al suggest the need for inexpensive, low power, and compact sensors with long-term stability, minimal cross-sensitivity, and fast response. This view has been largely validated and supported by the fuel cell and hydrogen infrastructure industries by the NREL/DOE Hydrogen Sensor Workshop held on June 8, 2011. Many of the issues preventing widespread adoption of best-available hydrogen sensing technologies available today outside of cost, derive from excessive false positives and false negatives arising from signal drift and unstable sensor baseline; both of these problems necessitate the need for unacceptable frequent calibration.

08 HYDROGEN↗

DOE OSTI2012

Concept of Operations for Nuclear Warhead Embedded Sensors

Embedded arms-control-sensors provide a powerful new paradigm for managing compliance with future nuclear weapons treaties, where deployed warhead numbers will be reduced to 1000 or less. The CONOPS (Concept of Operations) for use with these sensors is a practical tool with which one may help define design parameters, including size, power, resolution, communications, and physical structure. How frequently must data be acquired and must a human be present? Will such data be acquired for only stored weapons or will it be required of deployed weapons as well? Will tactical weapons be subject to such monitoring or will only strategic weapons apply? Which data will be most crucial? Will OSI's be a component of embedded sensor data management or will these sensors stand alone in their data extraction processes? The problem space is massive, but can be constrained by extrapolating to a reasonable future treaty regime and examining the bounded options this scenario poses. Arms control verification sensors, embedded within the warhead case or aeroshell, must provide sufficient but not excessively detailed data, confirming that the item is a nuclear warhead and that it is a particular warhead without revealing sensitive information. Geolocation will be provided by an intermediate transceiver used to acquire the data and to forward the data to a central processing location. Past Chain-of-Custody projects have included such devices and will be primarily responsible for adding such indicators in the future. For the purposes of a treaty regime a TLI will be verified as a nuclear warhead by knowledge of (a) the presence and mass of SNM, (b) the presence of HE, and (c) the reporting of a unique tag ID. All of these parameters can be obtained via neutron correlation measurements, Raman spectroscopy, and fiber optic grating fabrication, respectively. Data from these sensors will be pushed out monthly and acquired nearly daily, providing one of several verification layers in depth, including on-site inspections, NTM, declarations, and semi-annual BCC meetings. Human intervention will not be necessary. The sheer numbers, small size, and wide distribution of warhead TLIs will mandate the added level of remote monitoring that Embedded Sensors can provide. This multilayer protection will limit the need to increase the frequency of OSIs, by adding confidence that declared TLIs remain as declared and that no undeclared items enter the regime without the other States Party's knowledge. Acceptance of Embedded arms control Sensor technologies will require joint development by all State's Parties involved. Principles of operation and robustness of technologies must be individually evaluated to sustain confidence in the strength of this system against attack. Weapons designers must be assured that these sensors will in no way impact weapon performance and operation, will not affect weapons security and safety, and will have a neutral impact upon weapon system surety. Each State's Party will need to conduct an in depth review of their weapons lifecycle to determine where moves may be reduced to minimize vulnerabilities and where random selection may be used to minimize the ability to make undeclared changes. In the end Verification is a political measure, not a technical one. If the potential users can gain sufficient confidence in the application of Embedded arms control Sensors, they could constitute the final layer of glue to hold together the next Nuclear Arms Control agreement.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗

DOE OSTI2018

High-Temperature Sapphire Pressure Sensors for Harsh Environments

The project aimed to develop and characterize an optical pressure sensor capable of withstanding high temperatures, up to 1000 °C. Survivability in harsh environments was enabled using sapphire for both the substrate and the optical fibers, therefore mitigating thermal expansion mismatch. Such material cannot be machined through conventional microfabrication techniques, and unique additive and subtractive methods had to be studied and implemented. Subtractive methods included laser-machining the sapphire substrate using a picosecond laser machining tool. At first, the parameters of importance were theoretically and experimentally evaluated such that the fluence, the pulse spacing, and the number of passes were found to strongly influence the laser ablation process. A simulation tool was designed to predict the final pattern when inputting a set of parameters and a profile. This model was complemented with laser ablation material physics models and Bayesian uncertainty analysis for one dimensional and three dimensional ablation processes. An additive process called thermocompression bonding was studied in order to seal the diaphragm substrate to the back cavity. At first, bonding strength using this technique was examined using the chevron-notch method that allow to determine the fracture toughness of this bond. This parameter is independent of the geometry used and therefore can be extended to other geometries used in actual sensor bonding. A theoretical and experimental study of internal damage caused by the laser micromachining of the sapphire material was carried out. The research identified enhanced strength and fracture toughness along laser ablated surfaces. This was determined using bend bar specimens and Vicker’s microindentations. Softening of the plasticity behavior (as indicated by nanoindentation experiments) was also investigated using finite deformation plasticity modeling via a contact mechanics finite element simulation. Good correlations between experiments and the model were achieved to determine material parameters that can be used in future MEMS based sensor design and modeling to minimize sensor failure loads. The enhanced strength and fracture toughness was determined to be due to compressive residual stress near laser ablated surfaces. This was confirmed through x-ray spectra taken along different crystal structure planes in combination and Bayesian uncertainty analysis. The Bayesian analysis inferred the entire residual strain tensor (six components) and the residual stress tensor. The results illustrated compressive in-plane stress was the most likely cause of enhanced strength and toughness after laser machining. Due to major equipment failures, a parallel route for fabricating the sensor was taken, using commercially available sapphire removal method (subtractive) and ceramic adhesive bonding (additive). The fully-packaged sensor utilized laser micromachining for the sapphire substrate fabrication and was comprised only of high-temperature-compatible materials. Calibration tests of the sensor in both room-temperature and high-temperature plane-wave tubes showed good linearity and consistent frequency response, in the tested frequency range. The sensor also showed good thermal stability in tests up to 300 °C, proving the fiber-optic lever and its packaging process to be a promising approach for high-temperature measurements. The calibration from 23 °C to 300 °C gave a raw sensitivity of 3.9 × 10 -7 V/Pa and a normalized sensitivity of 9.8 × 10 -8 Pa -1 which were consistent within the temperature range. The sensor had a resonance at 16.3 kHz and a flat band (±3 dB) up to 10.3 kHz. The noise floor of the sensor at 1 kHz was 316 nV/Hz 1/2 , resulting in a MDP of 0.8 Pa. Previously, diaphragm delamination due to CTE mismatch was found at 500 °C, causing packaging failure. Unfortunately high temperature validation in hot jet environment could not be made in time. In the future, it is suggested that the two sapphire substrates be bonded by thermal compression bonding with an intermediate platinum layer instead of using an alumina-based adhesive, and therefore achieve higher temperature capacity up to 1000 °C.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

DOE OSTI2021

AOI [1]: Passive Wireless Sensor Systems Fabricated by Direct-Writing for Temperature and Health Monitoring of Energy Systems in Harsh-Environments (Final Report)

Researchers at West Virginia University (WVU) propose to demonstrate a wireless, high-temperature sensor system for monitoring the temperature and health of energy-system components. The active sensor and electronics for wireless communication will be composed entirely of an electroceramic materials (conductive ceramics) which are capable of withstanding the harsh-environments required for fossil energy-based technologies. This work will focus primarily on the fabrication and testing of temperature (thermocouples and thermistors) and health (strain/stress and crack propagation sensors) that function at extreme temperatures (up to 700-1700ºC). The electronics will accompany the high-temperature sensor, which will include a passive wireless communication circuit that allows the transmission of the data based on the LCR resonance principle to a near-by reader antenna. This passive transmission of data will reduce the need for interconnect wires near the active, and possibly rotating, energy-system component. The research will include process development to permit the 2D/3D direct-writing of the entire sensor and communication circuit onto the energy-system component. The direct-writing will be facilitated by using silicon-based polymer-derived precursors to form the high-temperature, stable electroceramic compositions. In addition, methods for direct-writing the circuit onto a fugitive carrier substrate will be completed, which will permit a “peel-and-stick”-like transfer of the sensor circuit to the energy-system component. This feature will allow the economical and precise placement of the sensor circuit onto components of various shapes and locations, without altering the geometry and active features of the manufactured component, or the removal (or decommissioning) of the component for installation. The proposed work will be directed at the following areas: 1) Investigation of phase formation, sintering/grain growth, and electrical properties of polymer-derived electroceramic composites; 2) Definition of processes to direct-write through ink-jet and robo-casting the polymer-derived electroceramic composites onto oxide and polymer surfaces; 3) Development of methods to form monolithic "peel-and-stick" preforms that will efficiently transfer the sensor circuit to ceramic surfaces after thermal treatment; 4) Design of passive wireless LCR circuits and receiver (reader) antennas for communication and testing at high temperatures; 5) Investigation of the passive wireless sensor system developed (and method of transferring sensor system) for temperature and stress/strain measurements on a SOFC repeat unit and a singular gas turbine blade prototype as example applications.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2023

Development of a Portable In Situ Phosphorous Sensor

While phosphorus is a critical nutrient for all forms of life, runoff leads to phosphorus accumulation in surface water where it can cause a variety of health, environmental, and economic problems. The Department of Energy is interested in conducting long-term field experiments to monitor the impact of phosphorus in terrestrial and aquatic environments, and to better understand a cost vs. benefit analysis of reducing phosphorus pollution. Performing such long-term experiments requires affordable sensors capable of monitoring low-level phosphorus concentrations under challenging environmental conditions. However, such sensors are currently not available. The goal of this proposed project is to develop and demonstrate a low-cost portable phosphorus sensor suitable for in situ measurements. We will determine the technical requirements for a Raman-based sensor system, design and build a signal amplifier, integrate it with a Raman-based sensor, and demonstrate a proof-of-concept level sensor system. The expected accomplishments for Phase I include the identification of the technical requirements of a combined Raman laser/spectrometer and cavity enhancement system, building a proof-of-concept level sensor system capable of detecting orthophosphate compounds at the desired level of 0.25 mg P/L and organic P compounds, and verification of the sensor performance under laboratory and field conditions. In addition, we will identify initial hardening requirements that will need to be implemented during Phase II. While we plan to develop an integrated sensor system for monitoring phosphorus, the cavity-based enhancement system can also be used in combination with other (non-phosphorus) Raman sensors that we plan to develop or that are already commercially available. A recent market report highlights the increasing demand for such environmental monitoring applications, with the market for chemical detection anticipated to grow at a compound annual growth rate of 6.5% (2020-2025). Wide-spread monitoring of phosphorus could reduce the damage from eutrophication in freshwater, which is estimated to be $2.2 billion annually, thereby increasing biodiversity, reducing costs required for drinking water treatment, and decreasing economic losses related to recreation and angling and lake property values.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2021

The NREL Sensor Laboratory: Status and Future Directions for Hydrogen Detection

The NREL Hydrogen Sensor Laboratory was commissioned in 2010 as a resource for the national and international hydrogen community to ensure the availability and proper use of hydrogen sensors. Since then, the Sensor Laboratory has provided unbiased verification of hydrogen sensor performance for sensor developers, end-users, and regulatory agencies and has also provided active support for numerous code and standards development organizations. Although sensor performance assessment remains a core capability, the mission of the NREL Sensor Laboratory has expanded toward a more holistic approach regarding the role of hydrogen detection and its implementation strategy for both assurance of facility safety as well as for process control applications. Active monitoring for detection of unintended releases has been identified by the NFPA 2 Storage Task Group as a viable approach for improving facility safety and lowering setbacks. The current research program for the Sensor Laboratory addresses both conventional and advanced developing detection strategies in response to the emerging large-scale markets, such as those envisioned by H2@Scale. These emerging hydrogen applications may require alternative detection strategies that supplement and may ultimately supplant the use of traditional sensors for monitoring hydrogen releases. Research focus areas for the NREL Sensor Laboratory now encompasses the characterization of released hydrogen behavior to optimize detection strategies for both indoor and outdoor applications, advanced methods of hydrogen leak detection such as hydrogen wide area monitoring approaches for large scale and distributed applications, the incorporation of active monitoring as a risk reduction strategy to improve safety at hydrogen facilities, and continuing support of hydrogen safety codes and standards. In addition to assurance of safety, detection will be critical for process control applications, such as hydrogen fuel quality verification for fuel cell vehicle applications and for monitoring and controlling of hydrogen-natural gas blend composition.

codes and standards↗

DOE OSTI2015

A MGy radiation-hardened sensor instrumentation link for nuclear reactor monitoring and remote handling

Decommissioning, dismantling and remote handling applications in nuclear facilities all require robotic solutions that are able to survive in radiation environments. Recently raised safety, radiation hardness and cost efficiency demands from both the nuclear regulatory and the society impose severe challenges in traditional methods. For example, in case of the dismantling of the Fukushima sites, solutions that survive accumulated doses higher than 1 MGy are mandatory. To allow remote operation of these tools in nuclear environments, electronics were used to be shielded with several centimeters of lead or even completely banned in these solutions. However, shielding electronics always leads to bulky and heavy solutions, which reduces the flexibility of robotic tools. It also requires longer repair time and produces extra waste further in a dismantling or decommissioning cycle. In addition, often in current reactor designs, due to size restrictions and the need to inspect very tight areas there are limitations to the use of shielding. A MGy radiation-hardened sensor instrumentation link developed by MAGyICS provides a solution to build a flexible, easy removable and small I and C module with MGy radiation tolerance without any shielding. Hereby it removes all these pains to implement electronics in robotic tools. The demonstrated solution in this poster is developed for ITER Remote Handling equipments operating in high radiation environments (>1 MGy) in and around the Tokamak. In order to obtain adequately accurate instrumentation and control information, as well as to ease the umbilical management, there is a need of front-end electronics that will have to be located close to those actuators and sensors on the remote handling tool. In particular, for diverter remote handling, it is estimated that these components will face gamma radiation up to 300 Gy/h (in-vessel) and a total dose of 1 MGy. The radiation-hardened sensor instrumentation link presented here, consists of multiple in-house developed, state-of-the-art building blocks. They have all been assessed and characterized up to a dose higher than 1 MGy. The first block in the signal chain is a smaller than 1 uV offset, low noise instrumentation amplifier that has a programmable gain between 8 and 256. This amplifier is followed by a high precision 16 bit ADC. Its main function is to digitize the amplified signal coming from the amplifier. The output of the ADC is a serial digital data stream. The next block is a 8 channel digital multiplexer. It converts the 8 digital data streams into 1 digital data stream. Hereby the instrumentation solution reduces the number of cables from 16 to 1 (8* 2 analogue differential signals). In addition, the multiplexer modules can be combined with other modules to reduce even further the number of cables. Every instrumentation solution requires a stable high precision voltage reference. Therefore also a bandgap reference has been developed and assessed under gamma irradiation. A low jitter, 10 MHz clock generator has been developed and qualified to clock the ADC and the multiplexer with high accuracy. Finally, an on-chip radiation-hard temperature sensor is also included. A complete remote, real-time test setup was prepared by MAGyICS in cooperation with Fusion for Energy to qualify the sensor instrumentation link at SCK-CEN. It is qualified by closely following the ESCC22900 space standard for electronics used in a radiation environment. The main benefit of the sensor instrumentation solution discussed here is that it can be directly employed in a MGy-level accumulated dose radiation environment, therefore it can digitize and multiplex sensor readout values early in the signal chain. Hereby the sensor values are not distorted by external interferences on the long transmission cable. Moreover it allows readout and digitize multiple low-bandwidth sensors ( pressure and temperature sensors, thermocouples, angular resolvers and LVDTs). Hence these instrumentation modules can be used to follow the trend of the digitalization in the nuclear industry. (authors)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2018

Investigation into the Development and Testing of a Simplex Capacitance Sensor for Rotor Tip Clearance Measurement in Turbo Machinery

The rotor tip clearance is a vital parameter to characterize turbomachinery performance. It is an essential measurement during engine development and testing. The efficiency of the major modules like fan, compressor and turbine depends on the optimum running clearances. The capacitive sensor is preferred for tip clearance measurements because of various inherent advantages. They are fabricated through complex processes for turbomachinery application and are expensive. These sensors are exposed to harsh engine environments and are likely to exhibit degraded performance. Insulation failure at sensing head, connector contamination and micro-cracks in the MI (Mineral Insulated) cable leads to noise in the signal output. Frequent mechanical failures are also seen due to work hardening of MI cables, lead connector detachments and failure of micro fins at interconnects. Fault fixing of these is tedious and very expensive. This paper presents the concerted effort in developing a simple capacitance sensor addressing potential sensor failure issues. The design features include simple construction, ease of sensor assembly, component realization and troubleshooting. The design also addresses all safety requirements. The sensor has a large sensing area (7.6 mm diameter) producing very stable, high-level signal. The developed sensor produces output that varies from 1 V{sub P-P} to 11 V{sub P-P} for blade-tip gaps between 3 mm to 0.4 mm respectively. Blade pass simulation studies across the sensor, display almost flat response at minimum clearance. This feature results in very minimal data acquisition errors. The sensor along with RC (Resistance-Capacitance) conditioning electronics was successfully used for clearance measurement on fan stage of gas turbine engine. Test results are in line with the predictions. Extensive tip clearance measurements on the engine validate the design. The current work provides an insight into the development of a simplex capacitance sensor for tip clearance measurement.

42 ENGINEERING↗

DOE OSTI2020

Metal-embedded fiber optic sensor packaging and signal demodulation scheme towards high-frequency dynamic measurements in harsh environments

Optical fiber-based sensors are commonly used for industrial monitoring and control processes due to their small size, resistance to electromagnetic interference, and ability to perform a wide variety of high-precision measurements. However, implementing optical fiber sensors in harsh environments is challenging because they are small and fragile. Proper packaging of fiber-optic sensors could extend their use to harsh environments, including at high temperature and under high radiation. Furthermore, conventional fiber optic-based measurement systems often use computationally expensive signal processing algorithms which hinder their use in high-frequency dynamic applications. This work reports on the design of an optical fiber-pressure sensor system based on low-coherence interferometry that uses a metal-embedded optical fiber to provide a robust sensor package. Additionally, a novel phase demodulation scheme is proposed to extract length changes from the deformation of a thin diaphragm within a Fabry–Pérot cavity to measure pressure. The sensor has been tested to ±100 kPa, has a theoretical linear response over a 270 kPa dynamic range (24 dB maximum signal-to-noise ratio), and can resolve pressure transients up to 3910 kPa/s. Sampling at 100 kHz, the present sensor can resolve 2 kPa dynamic pressures at frequencies up to 2 kHz. Faster transients on the order of tens to hundreds of kHz can theoretically be resolved at the expense of decreasing the maximum resolvable amplitude. A methodology for designing a LCI pressure sensor for a given application is outlined based on the limitations imposed by the Nyquist criterion, the diaphragm's resonant frequency, the LCI optoelectronics, and the phase demodulation scheme. The sensor is the first to implement a low-coherence light source and a Fabry–Pérot interferometer designed to provide real-time high-fidelity pressure measurements using a metal-embedded optical fiber. The demonstrated sensor provides a platform for sensing in harsh conditions such as in nuclear and energy applications.

47 OTHER INSTRUMENTATION↗

DOE OSTI2016

PEDOT:PSS/QCM-based multimodal humidity and pressure sensor

A room-temperature multimodal sensor composed of PEDOT:PSS deposited on an AT-cut quartz crystalmicrobalance (QCM) crystal has been fabricated. The nonlinear resistive and frequency sensor responses aredeconvolved using an articial neural network (ANN), which allows the single sensor to function simultane-ously as a relative humidity (RH) sensor and a pressure sensor using only two electrodes. We demonstratethat the predictive ability of the sensor is highly inuenced by the data used to train the ANN. When trainingsets are tailored to resemble the operating conditions of the sensor, the sensor achieves an average resolutionof < 3% RH from 0-100% RH, even after H 2 O saturation occurs on the surface. Our results indicate thatANNs show strong promise for improving the resolution of low cost gas sensors and for expanding the rangeof environmental conditions in which a given sensor can operate.

47 OTHER INSTRUMENTATION↗

DOE OSTI2024

Exceptional Electrical Detection of Trace NO 2 via Mixed Metal MOF-on-MOF Film-Based Sensors

The tunability of metal–organic frameworks (MOFs) makes them exceptional materials for the development of highly selective, low-power sensors for toxic gas detection. Herein, we demonstrate enhanced detection of NO 2 gas by a MOF-based electrical impedance sensor made using a unique mixed metal MOF-on-MOF synthesis. For this work, a combined experimental and computational study was performed using the exemplar Ni x Mg 1–x -MOF-74 to understand the fundamental structure–property relationships behind metal mixing and MOF film synthesis methods on sensor performance. Density functional theory results indicated that the presence of Ni in Mg-MOF-74 increased framework stability and increased the electron density of states at lower energies near the HOMO, as well as enhanced the NO 2 –Mg adsorption interaction. Impedance data of the Ni x Mg 1–x -MOF-74 films with larger Ni contents showed greater impedance change after exposure to 1 ppm of NO 2 gas. Furthermore, when synthesized through either a drop-cast or direct solvothermal film growth approach, the monometallic Ni-based sensors had the best performance. However, the mixed metal Ni x Mg 1–x -MOF-74 sensors synthesized through a MOF-on-MOF approach resulted in the highest impedance change, outperforming all monometallic Ni-based sensors. In particular, the mixed metal Ni-on-Mg-MOF-74 film was the best-performing sensor with an impedance change of 309 upon trace NO 2 exposure. Change in impedance response after NO 2 exposure was improved by 52% compared to the best monometallic Ni-on-Ni-MOF-74 sensor. Structural analysis of the Ni-on-Mg film showed that the first Mg-MOF-74 layer acts as a structural template controlling the structural features of the final film after metal exchange with Ni. This led to improved film quality, evidenced by the greater crystallinity and larger MOF grain sizes, and resulted in enhanced sensor performance which was not achievable through other metal mixing methods. Altogether, this study identifies structure–property relationships and synthetic templating methods that inform MOF-based sensor design, allowing for improved detection of toxic compounds.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Sensor Placement Optimization Software Applied to Site-Scale Methane-Emissions Monitoring

Advances in sensor technology have increased our ability to monitor a wide range of environments. However, even as the cost of sensors decline, only a limited number of sensors can be installed at any given site. The physical placement of sensors, along with the sensor technology and operating conditions, can have a large impact on our ability to adequately monitor environmental change. This paper introduces a new open-source Python package, called Chama, that determines optimal sensor placement and technology to improve a sensor network’s detection capabilities. Additionally, the methods are demonstrated using site-specific methane emission scenarios that capture uncertainty in wind conditions and emission characteristics. Mixed-integer linear programming formulations are used to determine sensor locations and detection thresholds that maximize detection of the emission scenarios. The optimized sensor networks consistently increase the ability to detect leaks, as compared to sensors placed near each potential emission source or along the perimeter of the site.

47 OTHER INSTRUMENTATION↗

DOE OSTI2017

Peel-and-Stick Sensors Powered by Directed RF Energy

PARC, a Xerox Company, is developing a low-cost system of peel-and-stick wireless sensors that will enable widespread building environment sensor deployment with the potential to deliver up to 30% energy savings. The system is embodied by a set of RF hubs that provide power to automatically located sensor nodes, and relay data wirelessly to the building management system (BMS). The sensor nodes are flexible electronic labels powered by rectified RF energy transmitted by an RF hub and can contain multiple printed and conventional sensors. The system design overcomes limitations in wireless sensors related to power delivery, lifetime, and cost by eliminating batteries and photovoltaic devices. Sensor localization is performed automatically by the inclusion of a programmable multidirectional antenna array in the RF hub. Comparison of signal strengths while the RF beam is swept allows for sensor localization, reducing installation effort and enabling automatic recommissioning of sensors that have been relocated, overcoming a significant challenge in building operations. PARC has already demonstrated wireless power and temperature data transmission up to a distance of 20m with less than one minute between measurements, using power levels well within the FCC regulation limits in the 902-928 MHz ISM band. The sensor’s RF energy harvesting antenna achieves high performance with dimensions below 5cm x 9cm

Lalau-Keraly, Christopher↗

DOE OSTI2012

Battery-free Wireless Sensor Network For Advanced Fossil-Fuel Based Power Generation

This report summarizes technical progress achieved during the project supported by the Department of Energy under Award Number DE-FG26-07NT4306. The aim of the project was to conduct basic research into battery-free wireless sensing mechanism in order to develop novel wireless sensors and sensor network for physical and chemical parameter monitoring in a harsh environment. Passive wireless sensing platform and five wireless sensors including temperature sensor, pressure sensor, humidity sensor, crack sensor and networked sensors developed and demonstrated in our laboratory setup have achieved the objective for the monitoring of various physical and chemical parameters in a harsh environment through remote power and wireless sensor communication, which is critical to intelligent control of advanced power generation system. This report is organized by the sensors developed as detailed in each progress report.

20 FOSSIL-FUELED POWER PLANTS↗