Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Thermal imaging”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 307 records · Page 17
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

FWP FEAA149: “Next Generation Environmental Barrier Coatings”

Environmental barrier coatings (EBCs) are required coatings for utilization of SiC/SiC ceramic matrix composite (CMC) components in gas turbines, where the EBC represents the life-limiting factor for such components. EBC/CMC systems have shown success in aero-engine applications with increased turbine inlet temperatures and improved efficiencies, which are achieved through higher temperature stability, lower density, and decreased reliance on cooling air compared to traditional superalloys. While industrial gas turbines (IGTs) do not currently utilize SiC/SiC CMCs, the current shift towards low-carbon or carbon-free fuel sources for power generation could result in a need for EBC/CMC components with higher temperature capabilities. In this work, three tasks were outlined to improve understanding of EBC lifetimes to encourage use in IGTs with carbon-free fuel such as hydrogen: 1. Define the bond coating oxidation kinetics and EBC failure criteria, 2. Measure thermal expansion coefficients of each layered material, and 3. Perform advanced characterization and modeling to assess EBC lifetimes. Cyclic steam oxidation tests were conducted on various EBC/Si/SiC chemistries and EBC/SiC architectures to define substrate oxidation kinetics and EBC failure modes. An open-source code was developed to quantify the undulating thermally grown oxide thickness with thousands of measurements from specimen cross-section images. Bond coating oxidation kinetics were determined and used to develop a kinetic and thermodynamic model for predicting EBC lifetimes. High-temperature Raman spectroscopy was utilized for determining the SiO 2 thermally grown oxide phase transformation as the life-limiting feature for EBCs. Model efforts supported the claim that the SiO 2 phase transformation causes elevated stress during thermal cycling with associated cracking that decreases the adhesion strength of the EBC, eventually resulting in coating spallation. The finite element model subroutine will be made publicly available upon internal review. Further development of an EBC lifetime model for IGTs involves definition of a critical SiO 2 thickness for EBC spallation and must also consider both environmental (gas velocity, pressure, etc.) and specimen (EBC dopants, layer architectures, etc.) effects into predicted bond coating oxidation kinetics for long-lifetime components.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Benchmarking of Solar Irradiance Nowcast Performance Derived from All-Sky Imagers

Fluctuations of the incoming solar irradiance impact the power generation from photovoltaic and concentrating solar thermal power plants. Accurate solar nowcasting becomes necessary to detect these sudden changes of generated power and to provide the desired information for optimal exploitation of solar systems. In the framework of the International Energy Agency's Photovoltaic Power Systems Program Task 16, a benchmarking exercise has been conducted relying on a bouquet of solar nowcasting methodologies by all-sky imagers (ASI). In this paper, four ASI systems nowcast the Global Horizontal Irradiance (GHI) with a time forecast ranging from 1 to 20 min during 28 days with variable cloud conditions spanning from September to November 2019 in southern Spain. All ASIs demonstrated their ability to accurately nowcast GHI, with RMSE ranging from 6.9% to 18.1%. Under cloudy conditions, all ASIs' nowcasts outperform the persistence models. Under clear skies, three ASIs are better than persistence. Discrepancies in the observed nowcasting performance become larger at increasing forecast horizons. The findings of this study highlight the feasibility of ASIs to reliably nowcast GHI at different sky conditions, time intervals and horizons. Such nowcasts can be used either to estimate solar power at distant times or detect sudden GHI fluctuations.

all-sky imagers↗
DOE OSTI2024

The atomic-level structure and stability of interfaces of Pt nanoparticles in alumina: An experimental and computational evaluation

The atomic-level structure of interfaces between Pt and a transition form of Al2O3 were studied using a combination of electron microscopy and first principles calculations. A model system of Pt nanoprecipitates in Al2O3 were formed in sapphire wafers via high-energy ion implantation of Pt followed by thermal annealing at 1000 °C in air. The Pt nanoparticles took the form of tetrahedra and truncated tetrahedra primarily bound by {111}Pt facets. The high prevalence of these facets motivated the development of density functional theory (DFT) based models of (111)Pt interfaces with six different chemical terminations of ( 2 ¯ 01 ) θ-alumina. The atomic-level structure of the Pt/Al2O3 interfaces was characterized with aberration-corrected scanning transmission electron microscopy (STEM) and the experimental images were compared to STEM image simulations of the DFT models. The model interface with Pt bonded to oxygen-terminated θ-Al2O3, with the Pt located on top of the O and with an underlying layer of octahedral Al, provided the best match to the experimental images. This interfacial termination is also the most stable for the thermal annealing conditions used based on thermodynamic calculations of the interfacial energy as a function of temperature and oxygen partial pressure. This experimentally verified model provides a basis for improving models of Pt/γ-alumina interfaces.

Clauser, A L↗
DOE OSTI2021

An innovative digital image correlation technique for in-situ process monitoring of composite structures in large scale additive manufacturing

As additive manufacturing (AM) continues to develop and become a standardized manufacturing method, there will be a continued need to provide in-situ monitoring during the manufacturing of polymer composite printed components. Thermal residual stress is a primary cause of failures such as interlayer disbonds or delamination, micro cracking, and dimensional instability, which can occur during or after the build. Here, we report a novel digital image correlation (DIC) adaptation to monitor thermal residual stresses during the entire print process for large-scale AM. In this work, DIC has been investigated (a) by the natural speckle produced by the polymer surface for correlation, (b) to monitor AM build, and (c) to evaluate the effect of thermal residual stress on warpage of the printed component. The natural speckle pattern of the AM material resulted in a respectable 3.57% error compared to the traditional painted speckle pattern of 3.05% error. DIC measured a 190% increase in vertical displacement at the edge of the wall compared to the center, indicating warpage during AM. This work is a step towards a non-intrusive residual stress measuring technique using DIC for large-scale AM.

36 MATERIALS SCIENCE↗
DOE OSTI2022

The Effect of Cell Geometry and Trigger Method on the Risks Associated with Thermal Runaway of Lithium-Ion Batteries

Consideration of thermal runaway heat output variability is paramount for the development of safe lithium-ion battery assemblies. This study utilizes data gathered from fractional thermal runaway calorimetry (FTRC) experiments to conduct a comparative analysis of thermal runaway heat output for three cell formats (18650, 21700, and 33600) as a function of trigger method (heaters, internal short-circuiting device, and nail penetration). The analysis is based on comparisons for the calculated total energy yield, fractional energy yield, heat rate, and heat flux. This study reveals that nail penetration tends to result in higher thermal runaway heat output for larger cells (21700 & 33600); these experiments also tended to result in higher fractions of the total energy being released through the cell body. The smaller cells (18650) did not appear to have significant variation in heat output as a function of trigger method. This finding suggests that, for this cell type, worst-case scenario heat output could be achievable in assembly level testing regardless of the utilized trigger method. This study also demonstrates successful translation of FTRC results, as recorded in the Battery Failure Databank, into meaningful analysis that breaks down the influence of specific conditions on thermal runaway heat output.

calorimetry↗
DOE OSTI2021

Multi-energy reconstructions, central electron temperature measurements, and early detection of the birth and growth of runaway electrons using a versatile soft x-ray pinhole camera at MST

A multi-energy soft x-ray pinhole camera has been designed, built, and deployed at the Madison Symmetric Torus to aid the study of particle and thermal transport, as well as MHD stability physics. This novel imaging diagnostic technique employs a pixelated x-ray detector in which the lower energy threshold for photon detection can be adjusted independently on each pixel. The detector of choice is a PILATUS3 100 K with a 450 μm thick silicon sensor and nearly 100 000 pixels sensitive to photon energies between 1.6 and 30 keV. An ensemble of cubic spline smoothing functions has been applied to the line-integrated data for each time-frame and energy-range, obtaining a reduced standard-deviation when compared to that dominated by photon-noise. The multi-energy local emissivity profiles are obtained from a 1D matrix-based Abel-inversion procedure. Central values of Te can be obtained by modeling the slope of the continuum radiation from ratios of the inverted radial emissivity profiles over multiple energy ranges with no a priori assumptions of plasma profiles, magnetic field reconstruction constraints, high-density limitations, or need of shot-to-shot reproducibility. In tokamak plasmas, a novel application has recently been tested for early detection, 1D imaging, and study of the birth, exponential growth, and saturation of runaway electrons at energies comparable to 100 × Te,0; thus, early results are also presented.

Delgado-Aparicio, L. F. (ORCID:0000000167394380)↗
DOE OSTI2023

Topological kinetic crossover in a nanomagnet array

Ergodic kinetics, which are critical to equilibrium thermodynamics, can be constrained by a system’s topology. Here, we studied a model nanomagnetic array in which such constraints visibly affect the behavior of the magnetic moments. In this system, magnetic excitations connect into thermally active one-dimensional strings whose motion can be imaged in real time. At high temperatures, our data showed the merging, breaking, and reconnecting of strings, resulting in the system transitioning between topologically distinct configurations. Below a crossover temperature, the string motion is dominated by simple changes in length and shape. In this low-temperature regime, the system is energetically stable because of its inability to explore all possible topological configurations. This kinetic crossover suggests a generalizable conception of topologically broken ergodicity and limited equilibration.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2021

A New Route to Quantum-Scale Structures through a Novel Enhanced Germanium Diffusion Mechanism

This project sought to develop a fundamental understanding of the mechanisms underlying a newly observed enhanced germanium (Ge) diffusion process in silicon germanium (SiGe) semiconductor nanostructures during thermal oxidation. Using a combination of oxidationdiffusion experiments, high resolution imaging, and theoretical modeling, a model for the enhanced Ge diffusion mechanism was proposed. Additionally, a nanofabrication approach utilizing this enhanced Ge diffusion mechanism was shown to be applicable to arbitrary 3D shapes, leading to the fabrication of stacked silicon quantum dots embedded in SiGe nanopillars. A new wet etch-based method for preparing 3D nanostructures for highresolution imaging free of obscuring material or damage was also developed. These results enable a new method for the controlled and scalable fabrication of on-chip silicon nanostructures with sub-10 nm dimensions needed for next generation microelectronics, including low energy electronics, quantum computing, sensors, and integrated photonics.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Multispectral and thermal surface imagery and surface elevation mosaics - SGP July 2022

This data set contains high-resolution image products (orthomosaics) acquired from midsized uncrewed aerial systems that have been processed for value-added quality. The instrument itself, a multispectral imager, the Altum by Micasense, captures six spectral bands (red, green blue, NIR, red edge, and LWIR/thermal1) as radiance, which is converted to reflectance via custom code. The code used to develop these images first uses tools from the Micasense Python library2 to apply dark level corrections, row gradient corrections, and radiometric corrections. Next, it uses the processing API from Agisoft Metashape software to align and mosaic the processed imagery, following the processes developed by the USGS' structure from motion workflow documentation.3 Captures at different altitudes (recorded in MSL) produce an orthomosaic, a tif image containing information related to the six spectral bands, and a digital elevation model (DEM), a tif image containing information related to the elevation of the surveyed terraine. Metadata included in every image can be used to extract lat, lon, and reflectance values. 1 https://www.arm.gov/publications/tech_reports/handbooks/doe-sc-arm-tr-281.pdf 2 https://micasense.github.io/imageprocessing/MicaSense%20Image%20Processing%20Setup.html 3 https://pubs.usgs.gov/of/2021/1039/ofr20211039.pdf

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2020

CryoTARPOS Vibration Mitigation System for Layered Experiments

The goal of this project is to implement a system that can eliminate or mitigate vibration so that clear images can be taken without bypassing the cryocooler. By allowing for layer characterization and cryocooler operation at the same time, cooling capacity and thermal stability of the target would be improved, and more layer characterization data could be taken. Increased cooling capacity and thermal stability could allow for layering during occasional off normal conditions that would typically result in a loss of temperature control and NIF operational delays ranging from several hours to several days per month. The increased cooling capacity and thermal stability could also allow for layering of new target platforms that have less cooling margin. Additional layer images could be used for better characterization of defects and non-uniformities in the layer and would reduce the likelihood of layer seed loss, which typically adds ~12 hours per week in layering time. Motion blur from vibration due to off normal activity in the NIF Target Bay could also be mitigated that would usually result in NIF operational delays of several hours every month.

42 ENGINEERING↗
DOE OSTI2020

Experimental system for studying temperature gradient-driven fracture of oxide nuclear fuel out of reactor

Temperature gradients in ceramic light water reactor (LWR) uranium dioxide (UO 2 ) nuclear fuel pellets generate thermal stresses that cause fractures in the fuel beginning early in the life of fresh fuel. The combination of heating due to fission and forced convective cooling on the exterior of LWR fuel rods generates a temperature profile that is difficult to replicate outside the reactor environment. In the present study, a state-of-the-art experimental set-up using electrical heating to replicate fission heating was built and surrogate fuel materials such as ceria (CeO 2 ) were used to validate the system. Cracking experiments were conducted on these surrogates by inducing reactivity-initiated-accident (RIA) like temperature gradients in the pellets via induction and direct resistance heating. Induction heating was done using copper coils and molybdenum susceptors which heated the surrogates to a threshold temperature that is sufficiently high for the fuel material to conduct current. Thereafter, direct resistance heating was used by a D.C. power supply to introduce volumetric heating to replicate LWR operating conditions analogous to fission heating. The pellets were held against nickel electrodes and mounted on a boron nitride test-stand. All the tests were carried out in a stainless-steel vacuum chamber. Simultaneous real-time dual imaging of the surrogate pellet surface has been implemented using an optical and infrared camera system which will be mounted along axial and perpendicular directions to the pellet surface respectively. A beam-splitter was used to split the incoming radiation from the sample into two halves. While one of the beams is transmitted from the splitter through a bandpass filter to obtain optical images, the other beam is reflected from the splitter to the thermal camera to capture full field temperature gradients of the as fabricated pellet surface during crack initiation and propagation. In the current series of tests, a 2-color pyrometer was used for recording and comparing the surface and centerline temperatures of the surrogate pellets in lieu of the thermal camera. A LabVIEW data acquisition system has been set up for collecting useful data during experiments.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Shape fluctuations and optical transition of He 2 * excimer tracers in superfluid He 4

Metastable He$_{2}^{*}$ excimer molecules have been utilized as tracer particles of the normal component in superfluid $^4$He (He II) which can be imaged via laser-induced fluorescence. These excimer molecules form tiny bubbles in He II and can bind to quantized vortices at sufficiently low temperatures, thereby allowing for direct visualization of vortex dynamics in an inviscid superfluid. However, the $a^{3}\Sigma^+_{u}$${\rightarrow}$$c^{3}\Sigma^+_{g}$ optical absorption line, which is responsible for the fluorescence imaging of the He$_{2}^{*}$ molecules, is controlled by fluctuations on the bubble shape, and its exact line profile is not known at low temperatures. In this paper, we present a bubble model for evaluating the surface fluctuation eigenmodes of the excimers in He II. The line profile of the $a^{3}\Sigma^+_{u}{\rightarrow}c^{3}\Sigma^+_{g}$ transition is calculated at different temperatures by considering both the zero-point and thermal fluctuations on the bubble shape. We show that, as the temperature drops from 2~K to 20 mK, the peak absorption strength is enhanced by a factor of about five, accompanying a blueshift of the peak location by about 2 nm. A double-peak line profile due to the rotational levels of the molecular core can be resolved. This bubble model also allows us to evaluate the stiffness of the He$_{2}^{*}$ bubbles and hence their diffusion constant in He II due to scattering off thermal phonons. Our results will aid the design of future experiments on imaging quantized vortices in He II using He$_{2}^{*}$ tracers.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2022

What lies beneath: Vertical temperature heterogeneity in a Mediterranean woodland savanna

As the availability of satellite and airborne thermal infrared remote sensing (TIR-RS) data increases and their spatial, temporal, and spectral resolutions improve, researchers are finding diverse applications for TIR-RS measurements. TIR-RS is now commonly applied in regional- and continental-scale analyses, such as those focused on fire and surface energy balance. However, its application lags in plant physiology and ecology, for which a finer-scale understanding of plant canopy temperatures would be useful to elucidate plant water dynamics, for example. In particular, while methods to disaggregate TIR-RS pixels in horizontal space have advanced, possible vertical stratification of plant canopy temperature and its implications for understanding the correspondence between TIR-RS and finer-scale, field-based thermal measurements (e.g. made with a thermal camera) remain unexplored. Here, we use data from a thermal camera deployed concurrently with the recent ECOSTRESS mission to quantify vertical temperature gradients within tree canopies and temperatures of over- vs. under-story plants in a Mediterranean woodland savanna. We then leverage diverse ancillary data to maximize the geometric comparability of ECOSTRESS and thermal camera measurements, in order to assess the extent to which the two forms of thermal measurements correspond. Specifically, we ask: (1) What are the patterns of intra-canopy and over- vs. under-story vertical temperature in a Mediterranean woodland savanna?, and (2) How can vertically-resolved, but spatially-limited field-based temperature measurements be reconciled with spatially-extensive, but surface-only, temperature measurements of a space-borne remote sensor? Further, we found consistent patterns of vertical thermal heterogeneity both within tree canopies and between ecosystem over- and under-stories. The daytime difference between the top and bottom thirds of blue oak canopies was, on average, 0.48 ° C – and sometimes several times larger. Notably, canopy tops are cooler, likely associated with the under-story grass reaching daytime temperatures often exceeding over-story temperatures by 10° C. Given the consistency of the intra-canopy temperature gradients, we expected the ECOSTRESS sensor would be in better agreement with camera measurements of canopy tops than bulk canopies or canopy bottoms. However, within-canopy gradients were overwhelmed by other sources of disagreement between the measurements, in part associated with upscaling camera measurements across space. Overall, thermal camera and ECOSTRESS measurements were largely in agreement at night (pixel RMSE = 1.1°C), but they were more divergent during times of low (but >0 W/m2) and high incoming solar radiation (daytime pixel RMSE = 3.5°C).

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2026

In-situ sensor monitoring of multi-class gas porosity formation in laser powder bed fusion using convolutional neural network

In-situ monitoring of defect formation remains a significant challenge in the laser powder bed fusion (LPBF) process. Recent advances have enabled real-time defect detection with machine learning and in-situ sensing technologies; however, most studies focus on binary classification of keyhole pores, limiting nuanced multi-class pore differentiation and formation mechanisms. This work introduces a multi-class pore detection framework (no pore, small pores < 15 µm, and large pores > 15 µm) by leveraging photodiode sensor data alongside high-fidelity synchrotron X-ray imaging. The 15 µm threshold is selected to distinguish between two fundamentally different defect mechanisms, following the physical size-mechanism boundary established by prior high-resolution synchrotron X-ray characterization of Al6061 LPBF. Distinguishing these classes is critical because large keyhole pores are structurally detrimental, whereas small gas pores are often benign, requiring different process control strategies. Thermal emission monitoring data collected simultaneously with high-speed X-ray imaging at the Stanford Synchrotron Radiation Lightsource (SSRL), are correlated with subsurface melt pool dynamics to establish ground truth. Continuous Wavelet Transform (CWT) with optimized parameters converts the photodiode time-series signals into time–frequency images, facilitating feature extraction. Convolutional Neural Networks (CNN) are then applied for real-time multi-class pore classification in an average inference time of 1 ms per signal window. It achieves 79% accuracy and an Area Under the Receiver Operating Characteristic curve (AUC ROC) score of 0.89 with five-fold cross-validation. The results demonstrate that coupling CWT-based feature engineering with CNN architecture enables reliable multi-class pore detection in Al6061 builds using affordable in-situ sensors. This approach advances scalable and affordable quality assurance in additive manufacturing by moving beyond binary defect detection toward more nuanced classification of porosity mechanisms with in-situ sensors and machine learning.

Laser powder bed fusion, Multi-class pores, In-sit↗
DOE OSTI2022

Development and Validation of Resistance-Capacitance Model (RCM) for Phase Change Material (PCM) Embedded in 3D Periodic Structures

The low thermal conductivity of Phase Change Materials (PCM) can be improved with extended surfaces such as additively manufactured 3D periodic lattice structures. Three different aluminum alloy-based lattices (base sizes 10, 20, and 40 mm) with average porosity of 0.95 filled with paraffin wax, with a nominal phase change temperature of 55°C, were experimentally investigated. In this work, a computationally efficient 2D Resistance Capacitance-based model (RCM) was developed for predicting the thermal characteristics of these geometries. Non-uniform porosity in the PCM-metal domain was estimated using image processing and served as model input. The solver does not solve for higher-order physics as in CFD but still can provide a good prediction of thermal resistance and energy storage at a very low computational cost. The simulation-to-real-time factor for this geometry is of the order of 10-4, while CFD simulations typically have a real-time factor greater than 1. The model was validated against the experimental data for melting under three different heat fluxes (6250 W/m2, 12500 W/m2, and 18750 W/m2). The mean deviation of the predicted average PCM temperature was between 1.34 K-2.81 K for different cases. The maximum average temperature deviation of 5.45 K was observed for the 20 mm geometry at the highest heat flux test condition. The effects of natural convection were neglected in the model, but the predicted PCM temperature and energy storage still showed good agreement with the experimental data.

25 ENERGY STORAGE↗
DOE OSTI2020

The road to atomically thin metasurface optics

Abstract The development of flat optics has taken the world by storm. The initial mission was to try and replace conventional optical elements by thinner, lightweight equivalents. However, while developing this technology and learning about its strengths and limitations, researchers have identified a myriad of exciting new opportunities. It is therefore a great moment to explore where flat optics can really make a difference and what materials and building blocks are needed to make further progress. Building on its strengths, flat optics is bound to impact computational imaging, active wavefront manipulation, ultrafast spatiotemporal control of light, quantum communications, thermal emission management, novel display technologies, and sensing. In parallel with the development of flat optics, we have witnessed an incredible progress in the large-area synthesis and physical understanding of atomically thin, two-dimensional (2D) quantum materials. Given that these materials bring a wealth of unique physical properties and feature the same dimensionality as planar optical elements, they appear to have exactly what it takes to develop the next generation of high-performance flat optics.

Brongersma, Mark L.↗
DOE OSTI2021

A differential emissivity imaging technique for measuring hydrometeor mass and type

Abstract. The Differential Emissivity Imaging Disdrometer (DEID) is a new evaporation-based optical and thermal instrument designed to measure the mass, size, density and type of individual hydrometeors as well as their bulk properties. Hydrometeor spatial dimensions are measured on a heated metal plate using an infrared camera by exploiting the much higher thermal emissivity of water compared with metal. As a melted hydrometeor evaporates, its mass can be directly related to the loss of heat from the hotplate assuming energy conservation across the hydrometeor. The heat loss required to evaporate a hydrometeor is found to be independent of environmental conditions including ambient wind velocity, moisture level and temperature. The difference in heat loss for snow vs. rain for a given mass offers a method for discriminating precipitation phase. The DEID measures hydrometeors at sampling frequencies of up to 1 Hz with masses and effective diameters greater than 1 µg and 200 µm, respectively, determined by the size of the hotplate and the thermal camera specifications. Measurable snow water equivalent (SWE) precipitation rates range from 0.001 to 200 mm h−1, as validated against a standard weighing bucket. Preliminary field experiment measurements of snow and rain from the winters of 2019 and 2020 provided continuous automated measurements of precipitation rate, snow density and visibility. Measured hydrometeor size distributions agree well with canonical results described in the literature.

47 OTHER INSTRUMENTATION↗