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DOE OSTI2023

Unified Software Architecture for Advanced Materials and Manufacturing Technologies Data Management and Processing: FY 2023 Multidimensional Data Correlation Platform

This report details the various digital manufacturing activities ongoing at ORNL as part of the Advanced Materials and Manufacturing Technologies (AMMT) program. The AMMT program is exploring a data-driven approach to demonstrate the use of AM for the fabrication of components for nuclear applications, with the goal of providing a greater understanding of manufacturing quality outcomes that would pave the way toward the development of standards for certification and qualification. The objective of this work package is to establish a digital manufacturing discipline common to all participants of the AMMT program to improve the performance, reliability, and lifetime of nuclear components. As part of this effort, we will develop a unified software architecture for AMMT data management and processing, deploy the digital platform across AMMT participants’ facilities, and generate pedigreed datasets in a common format across multiple labs and facilities. To this end, the MDDC work package has focused on three activities during FY23. First, the MDF Digital Tool was overhauled to better serve the needs of the AMMT program. Next, multiple laser powder bed fusion (L-PBF) systems at the MDF were upgraded to a common sensor package for collecting comparable in situ data across machines. Finally, various improvements relevant to the AMMT program were implemented in the ORNL-developed software tool, Peregrine. This report marks the completion of FY23 milestone M3CR-22OR0403051: Report Describing the Architecture of the Digital Platform to Support AMMT Activities.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Open World Dempster-Shafer Theory/The Transferable Belief Model with Intervals: A Practitioner's Guide to DST and TBM

Dempster-Shafer theory (DST) is a mathematical framework that allows for uncertainty or ignorance to be quantified and included when making predictions from evidence. This is in contrast to Bayesian theory, which does not allow for any quantification of ignorance. The framework is described in great detail in [7]. DST is particularly useful for problems where the inclusion of additional evidence (for example, data from another sensor) could lead to a different conclusion. Thus, it is a useful data fusion method, especially in applications not suited to maximum likelihood or maximum a posteriori estimations due to limited samples or incomplete prior knowledge.

97 MATHEMATICS AND COMPUTING↗

NASA NTRS1989

Integration of active and passive sensors for obstacle avoidance

The automatic obstacle-avoidance guidance problem is studied under the operational constraints imposed by the rotorcraft nap-of-the-earth (NOE) environment. The problem is discussed for two different circumstances. The first assumes that a full range map is available, irrespective of the type of sensor being used. Two approaches are proposed to extend a two-dimensional obstacle-avoidance concept presented by Cheng (1988). The situation where only a sparse range map is available from a passive sensor is also treated. An integrated approach that augments the passive sensor with an active one is discussed, along with the problem of data fusion and how it is affected by the characteristics of NOE flight.

Cheng, Victor H. L.↗

DOE OSTI2023

A Data-Driven Framework for Direct Local Tensile Property Prediction of Laser Powder Bed Fusion Parts

This article proposes a generalizable, data-driven framework for qualifying laser powder bed fusion additively manufactured parts using part-specific in situ data, including powder bed imaging, machine health sensors, and laser scan paths. To achieve part qualification without relying solely on statistical processes or feedstock control, a sequence of machine learning models was trained on 6299 tensile specimens to locally predict the tensile properties of stainless-steel parts based on fused multi-modal in situ sensor data and a priori information. A cyberphysical infrastructure enabled the robust spatial tracking of individual specimens, and computer vision techniques registered the ground truth tensile measurements to the in situ data. The co-registered 230 GB dataset used in this work has been publicly released and is available as a set of HDF5 files. The extensive training data requirements and wide range of size scales were addressed by combining deep learning, machine learning, and feature engineering algorithms in a relay. The trained models demonstrated a 61% error reduction in ultimate tensile strength predictions relative to estimates made without any in situ information. Lessons learned and potential improvements to the sensors and mechanical testing procedure are discussed.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Contextually aware roadside radiation measurement testbed

Here we demonstrate a contextually aware multimodal roadside radiation measurement detection testbed for traffic monitoring applications in nuclear nonproliferation. Many variables in traffic such as vehicle or cargo size, mass, speed, shape, and distance of closest approach can have significant impacts on the radiation measured from a vehicle-transported radiation source. These factors can lead to uncertainties in the analysis of the radiation source, especially for lower-strength radiation sources of interest. Our testbed, known as the Multimodal Measurement System (MMS) uses non-radiation sensors including magnetometers, geophones, radiofrequency receivers, cameras, and LiDAR to extract contextual information about vehicles passing by the system. These contextual data can then be fused with data from radiation measurements to increase the system’s sensitivity and accuracy in nuclear threat detection applications. This work describes the instrumentation of the MMS and its data acquisition pipeline. Furthermore, we describe the pre-analysis performed on the raw multimodal data streams for data fusion, and the high-level machine learning analyses for detection and characterization. The variety of sensors within the MMS provides a valuable testbed that can be used to identify the combinations of contextual sensors that provide the greatest improvements to radiation source detection and characterization within the restrictions for various proliferation detection applications. The MMS is also modular so that additional combinations of sensors can be explored in the future.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2022

MAGNETICALLY SUSPENDED CANNED ROTOR PUMPS FOR THE INTEGRAL MOLTEN SALT REACTOR

This project developed a molten salt pump design for small modular reactors, concentrated solar, and Gen IV nuclear reactors with a magnetically levitated rotor that can operate at temperatures of up to 700 °C. This eliminates the need for rotating seals and roller element bearings which require maintenance and are prone to failure. The pump design is also more compact than existing molten salt pump designs which require long shafts to thermally isolate the electric motor. The aims of the project are to: 1) design and test the molten salt pump, 2) develop and test a high temperature position sensor needed for magnetic bearing control, and 3) develop and test high temperature coil fabrication methods for electric motor and magnetic bearing fabrication. To develop the high temperature coils, conductor materials were analyzed for oxidation, diffusion, cladding, and resistivity. Of the candidate conductor materials that met the requirements, silver was chosen. The long-term impact of radiation on silver resistivity was analyzed by developing a model of a generic molten salt fast reactor to model the conductor irradiation in worst case scenarios. The analysis showed that increased resistivity due to transmutation of silver decreases exponentially with the reactor reflector thickness. Different electrical insulation materials were tested and the final high temperature coils developed were able to withstand conductor to ground voltages up to 1800 V before insulation breakdown. Magnetic bearings require high-precision high-speed measurements of the rotor position to operate. Current commercial position sensors can only operate up to 550 °C so a novel position sensor was developed that can operate up to 800 °C. These sensors were also designed to measure the position of the metallic rotor through a thin metallic corrosion barrier that protects that coils, insulation, and magnetic cores so that the salt containment barrier does not have any penetrations. The high-temperature sensor was tested and had comparable performance to commercially available inductive position sensors. The sensor design and signal processing has led to several invention disclosures. The magnetically levitated molten salt pump design was completed and analyzed. The chloride salt test loop at Oak Ridge National Laboratory was chosen to test the pump and the pump hydraulics and power were designed for the test loop flow and pressure requirements. Classes of motor designs that do not utilize permanent magnetic were considered for the high-temperature motor. After extensive analysis of their performance, a synchronous reluctance motor was chosen for the pump. The design was refined and analyzed to optimize performance. The magnetic bearings were designed to meet the force and frequency requirements necessary to levitate the rotor and reject disturbances from rotor imbalance, motor forces, and hydraulic forces. Compliant mounts for the position sensors were designed that would not damage the ceramic sensor components and maintain sensor alignment over a wide temperature range. A thermal hydraulic analysis of the molten salt coolant flow used to cool the rotor and stator was performed to ensure that the maximum temperature in the rotor and stator will not exceed 725 °C. The corrosion barrier and casing were designed to maintain the salt fluid boundary by using compliant features to absorb large expansion mismatches due to different coefficients of thermal expansion (CTE). Finally, the salt drain and fill systems were designed along with the pump support structure, integration with the test loop, and thermal insulation and heating. Corrosion barrier fabrication experiments were performed to assess using laser cladding to apply a sub-millimeter corrosion barrier to the surface of a Fe-Co-V magnetic core material. The cladding method showed minimal mixing between materials at their interface and withstood temperature cycling without damage to the cladding. The technology commercialization is focused on the high-temperature position sensors and there has been significant interest from the nuclear industry in utilizing these sensors along with some interest from the aerospace industry. The project also led to a research collaboration with a fusion energy industrial partner to study barriers to scaling the pump design from the kW size to the MW size. This research collaboration will also study methods to create high-temperature coils that have conductor to ground breakdown voltages above 5 kV. The successful development of high-temperature electromagnetic coils and high-temperature position sensors greatly increases the temperature limits for electromagnetic devices that don’t rely on permanent magnets. This includes electric motors, magnetic bearings, linear actuators, rotary position and velocity sensing, actuated valves, and generators to name a few. This will fill a current need in molten salt reactors, concentrated solar, and fusion energy for these critical peripheral devices needed for practical reactor designs that do not currently have commercial solutions.

Hines, J Wesley↗

DOE OSTI2020

STAIR 2.0: A Generic and Automatic Algorithm to Fuse Modis, Landsat, and Sentinel-2 to Generate 10 m, Daily, and Cloud-/Gap-Free Surface Reflectance Product

Remote sensing datasets with both high spatial and high temporal resolution are critical for monitoring and modeling the dynamics of land surfaces. However, no current satellite sensor could simultaneously achieve both high spatial resolution and high revisiting frequency. Therefore, the integration of different sources of satellite data to produce a fusion product has become a popular solution to address this challenge. Many methods have been proposed to generate synthetic images with rich spatial details and high temporal frequency by combining two types of satellite datasets—usually frequent coarse-resolution images (e.g., MODIS) and sparse fine-resolution images (e.g., Landsat). In this paper, we introduce STAIR 2.0, a new fusion method that extends the previous STAIR fusion framework, to fuse three types of satellite datasets, including MODIS, Landsat, and Sentinel-2. In STAIR 2.0, input images are first processed to impute missing-value pixels that are due to clouds or sensor mechanical issues using a gap-filling algorithm. The multiple refined time series are then integrated stepwisely, from coarse- to fine- and high-resolution, ultimately providing a synthetic daily, high-resolution surface reflectance observations. We applied STAIR 2.0 to generate a 10-m, daily, cloud-/gap-free time series that covers the 2017 growing season of Saunders County, Nebraska. Moreover, the framework is generic and can be extended to integrate more types of satellite data sources, further improving the quality of the fusion product. View Full-Text

47 OTHER INSTRUMENTATION↗

DOE OSTI2023

Embedding thermocouples in SS316 with laser powder bed fusion

Recent advances in manufacturing technologies have enabled the fabrication of complex geometries for a wide range of applications, including the energy, aerospace, and civil sectors. The ability to integrate sensors at critical locations within these complex components during the manufacturing process could benefit process monitoring and control by reducing reliance on models to relate surface measurements to internal phenomena. This study investigated embedding thermocouples in a SS316 matrix using laser powder bed fusion. Under optimal processing conditions, embedded thermocouples were characterized post-building, finding good bonding to the matrix with no melt pool penetration to the sensing elements. Futher, the embedded thermocouple performed similarly to an identical non-embedded thermocouple during thermal testing to 500 °C with only a slight difference in response time, which was attributed to the differences in mass and the associated thermal time constants.

image analysis↗

DOE OSTI2025

Fiber-optic bolometers with high-temperature tolerance and reduced time constants for fusion plasma diagnostics

Fiber-optic bolometers (FOBs) designed for plasma radiation measurement in magnetically confined fusion environments have been previously developed and tested at the DIII-D tokamak. These FOBs utilize a silicon Fabry–Perot interferometer at the fiber tip for temperature measurement and a gold disk as a radiation absorber. This paper presents recent advancements in the development of FOBs with reduced cooling time constants and enhanced temperature tolerance. We also demonstrate high-temperature operation and report findings from irradiation tests. By incorporating a copper sensor holder as a thermal sink and integrating two closely packed sensor heads into a compact design, the cooling time constants were reduced to ∼100 ms in vacuum, while minimizing uncertainties caused by temperature gradients. The FOBs were subjected to heating at 400 °C for five hours, with no observed degradation in noise performance post-heating. High-temperature operation tests were conducted at ∼220 °C using a 404 nm square-wave modulated laser to simulate the plasma radiation. In addition, four FOBs constructed from copper-coated pure-silica fibers were fabricated and underwent irradiation testing, enduring a total γ-radiation dose of 15.2 MGy and a neutron fluence of 1.6 × 10 18 n/cm 2 . As a result, the FOBs maintained their physical integrity and the optical signal shows high visibility throughout the test.

42 ENGINEERING↗

NASA NTRS1993

Interactive and cooperative sensing and control for advanced teleoperation

This paper presents the paradigm of interactive and cooperative sensing and control as a fundamental mechanism of integrating and fusing the strengths of man and machine for advanced teleoperation. The interactive and cooperative sensing and control is considered as an extended and generalized form of traded and shared control. The emphasis of interactive and cooperative sensing and control is given to the distribution of mutually nonexclusive subtasks to man and machine, the interactive invocation of subtasks under the man/machine symbiotic relationship, and the fusion of information and decisionmaking between man and machine according to their confidence measures. The proposed interactive and cooperative sensing and control system is composed of such major functional blocks as the logical sensor system, the sensor-based local autonomy, the virtual environment formation, and the cooperative decision-making between man and machine. The Sensing-Knowledge-Command (SKC) fusion network is proposed as a fundamental architecture for implementing cooperative and interactive sensing and control. Simulation results are shown.

Lee, Sukhan↗

DOE OSTI2023

Photoluminescence Induced in Mineral Oil by Ionizing Radiation

We have studied photoluminescence (PL) properties of vacuum pump mineral oil as a function of the type and intensity of ionizing radiation exposure. The mineral oil has a simple aliphatic structure, which possesses no chromophore in the traditional sense. Unexpected PL in the mineral oil has characteristic features such as variation of the emission peak wavelength depending on the excitation wavelength and intensity dramatically increasing with radiation dose. The observed behavior can be understood in the framework of a previously suggested model introducing aggregation-induced PL and the formation of conjugated clusters comprising nontraditional chromophores. Our findings can be used for the development of optical sensors for real-time monitoring of oil utilized in vacuum pumps in nuclear fusion reactors.

Bliznyuk, Valery N.↗

NASA NTRS1990

Evolution of an Intelligent Information Fusion System

Consideration is given to the hardware and software needed to manage the enormous amount and complexity of data that the next generation of space-borne sensors will provide. An anthology is presented illustrating the evolution of artificial intelligence, science data processing, and management from the 1960s to the near future. Problems and limitations of technologies, data structures, data standards, and conceptual thinking are addressed. The development of an end-to-end Intelligent Information Fusion System that embodies knowledge of the user's domain-specific goals is proposed.

Campbell, William J.↗

NASA NTRS2005

Design Methods and Practices for Fault Prevention and Management in Spacecraft

Integrated Systems Health Management (ISHM) is intended to become a critical capability for all space, lunar and planetary exploration vehicles and systems at NASA. Monitoring and managing the health state of diverse components, subsystems, and systems is a difficult task that will become more challenging when implemented for long-term, evolving deployments. A key technical challenge will be to ensure that the ISHM technologies are reliable, effective, and low cost, resulting in turn in safe, reliable, and affordable missions. To ensure safety and reliability, ISHM functionality, decisions and knowledge have to be incorporated into the product lifecycle as early as possible, and ISHM must be considered as an essential element of models developed and used in various stages during system design. During early stage design, many decisions and tasks are still open, including sensor and measurement point selection, modeling and model-checking, diagnosis, signature and data fusion schemes, presenting the best opportunity to catch and prevent potential failures and anomalies in a cost-effective way. Using appropriate formal methods during early design, the design teams can systematically explore risks without committing to design decisions too early. However, the nature of ISHM knowledge and data is detailed, relying on high-fidelity, detailed models, whereas the earlier stages of the product lifecycle utilize low-fidelity, high-level models of systems and their functionality. We currently lack the tools and processes necessary for integrating ISHM into the vehicle system/subsystem design. As a result, most existing ISHM-like technologies are retrofits that were done after the system design was completed. It is very expensive, and sometimes futile, to retrofit a system health management capability into existing systems. Last-minute retrofits result in unreliable systems, ineffective solutions, and excessive costs (e.g., Space Shuttle TPS monitoring which was considered only after 110 flights and the Columbia disaster). High false alarm or false negative rates due to substandard implementations hurt the credibility of the ISHM discipline. This paper presents an overview of the current state of ISHM design,and a review of formal design methods to make recommendations about possible approaches to enable the ISHM capabilities to be designed-in at the system-level, from the very beginning of the vehicle design process.

Tumer, Irem Y.↗

NASA NTRS2006

An Overview of Inter-comparison Methodologies for Terra and Aqua MODIS Calibration

With increasing efforts on data fusion and long-term climate data records (CDR) using observations made by multiple sensors, on the same or different platforms, their cross-calibration and validation work has become more and more important. The uncertainties of the climate models and data records depend not only on the calibration quality of individual sensors but also on their calibration consistency. This paper provides an overview of methodologies used by the MODIS Characterization Support Team (MCST) at NASA GSFC for the inter-comparison studies of Terra and Aqua MODIS on-orbit calibration. Each MODIS was built with a set of onboard calibrators (OBC) that include a blackbody (BB), a solar diffuser (SD), and a solar diffuser stability monitor (SDSM). The BB is primarily used for the thermal emissive bands (TEB) calibration and the SD/SDSM system for the reflective solar bands (RSB) calibration. Although the-instrument design and calibration approach are nearly identical for both Terra and Aqua MODIS and they all went through an extensive and similar pre-launch calibration and characterization process, still their on-orbit calibration consistency needs to be carefully examined and validated as many science products have been generated from observations made by both instruments. Methodologies discussed in this paper include inter-comparison studies using the Moon, a third sensor, and ground targets. Our results show that Terra and Aqua reflective solar bands and thermal emissive bands have been calibrated consistently with excellent long-term stabilities. For the 11 and 12 micrometers sea surface temperature (SST) bands, the calibration difference of Terra and Aqua MODIS is less than 0.2K.

Xiong, X.↗

DOE OSTI2023

Analysis and mitigation of an oscillating background on hybrid complementary metal-oxide semiconductor (hCMOS) imaging sensors at the National Ignition Facility

Nanosecond-gated hybrid complementary metal-oxide semiconductor imaging sensors are a powerful tool for temporally gated and spatially resolved measurements in high energy density science, including inertial confinement fusion, and in laser diagnostics. However, a significant oscillating background excited by photocurrent has been observed in image sequences during testing and in experiments at the National Ignition Facility (NIF). Characterization measurements and simulation results are used to explain the oscillations as the convolution of the pixel-level sensor response with a sensor-wide RLC circuit ringing. Finally, data correction techniques are discussed for NIF diagnostics, and for diagnostics where these techniques cannot be used, a proof-of-principle image correction algorithm is presented.

42 ENGINEERING↗

NASA NTRS1999

Dynamics of the Molten Contact Line

The purpose of this program is to develop a basic understanding of how a molten material front spreads over a solid that is below its melting point, arrests, and freezes. Our hope is that the work will contribute toward a scientific knowledge base for certain new applications involving molten droplet deposition, including the "printing" of arbitrary three-dimensional objects by precise deposition of individual molten microdrops that solidify after impact. Little information is available at this time on the capillarity-driven motion and arrest of molten contact line regions. Schiaffino and Sonin investigated the arrest of the contact line of a molten microcrystalline wax spreading over a subcooled solid "target" of the same material. They found that contact line arrest takes place at an apparent liquid contact angle that depends primarily on the Stefan number S=c(T(sub f) -T(sub t)/L based on the temperature difference between the fusion point and the target temperature, and proposed that contact line arrest occurs when the liquid's dynamic contact angle approaches the angle of attack of the solidification front just behind the contact line. They also showed, however, that the conventional continuum equations and boundary conditions have no meaningful solution for this angle. The solidification front angle is determined by the heat flux just behind the contact line, and the heat flux is singular at that point. By comparing experiments with numerical computations, Schiaffino and Sonin estimated that the conventional solidification model must break down within a distance of order 0.1 - 1 microns of the contact line. The physical mechanism for this breakdown is as yet undetermined, and no first-principles theory exists for the contact angle at arrest. Schiaffino and Sonin also presented a framework for understanding how to moderate Weber number molten droplet deposition in terms of similarity laws and experimentation. The study is based on experiments with three molten materials- molten wax on solid wax, water on ice, and mercury on frozen mercury- which between them span a considerable range of the deposition/solidification similarity parameters. Correlations are obtained for the spreading velocity, spreading time scales, the spreading factor (i.e. ratio of deposited drop's final footprint radius and the drop's initial radius), post-spreading liquid oscillation amplitudes and time scales, and bulk solidification time scales. Duthaler carried out an experimental and theoretical investigation of the relationship between the liquid's apparent contact angle and the Capillary number Ca=mu U/sigma based on contact line speed, for molten materials spreading over subcooled solids. This relationship is required for modeling of melt spreading. We have adapted Voinov's methodology to the molten contact line and formulated a theoretical model for the Ca vs. contact angle relationship, based Schiaffino and Sonin#s (1997a,b) wedge-like solidification front model. With the solidification front angle taken from Schiaffino and Sonin, the model is in good agreement with the experimental results for Ca vs. contact angle. Duthaler also extended the experimental investigation of droplet deposition and contact line freezing to more materials, including solder on glass, solder on solder, water on ice, and molten microcrystalline wax on wax. The latter also included tests on inclined targets. Deposition tests have also been done with molten octacosane (C28H58) on various targets. An important objective of our program has been the development of micron-scale sensors for measuring the transient temperature at a point on the substrate surface as a molten contact line moves over it. The expectation is that this temperature history will yield a better understanding of the thermal process in the contact line region. The sensors are of the thermistor type, either 2.5 microns or 1.5 microns square, microfabricated with silicon-based technology on either pure silicon or amorphous silicon dioxide chips. Each chip has 32 sensors distributed on its surface in arrays. The time response is better than 10 ms. At the time of writing, sensor calibration is in progress. Results on thermal transients during contact line passage will be discussed at the conference. While we expect that the data will provide information on the near-contact-line heat transfer process, we also foresee possible problems. First, the spatial resolution of the sensors may be insufficient to resolve the near-contact-line region. Second, the sensors protrude about 0.5 microns above the substrate surface, and may affect the contact line motion. Third, a sensor's temperature history depends on both the heat flux distribution into it from the fusion front and the thermal properties of the substrate below it and the solidified melt between it and the fusion front. The heat flux distribution in the contact line region must therefore be unfolded from computations of the overall system's transient thermal response.

Sonin, Ain A.↗

NASA NTRS2002

Probabilistic #D data fusion for multiresolution surface generation

In this paper we present an algorithm for adaptive resolution integration of 3D data collected from multiple distributed sensors. The input to the algorithm is a set of 3D surface points and associated sensor models. Using a probabilistic rule, a surface probability function is generated that represents the probability that a particular volume of space contains the surface. The surface probability function is represented using an octree data structure; regions of space with samples of large conariance are stored at a coarser level than regions of space containing samples with smaller covariance. The algorithm outputs an adaptive resolution surface generated by connecting points that lie on the ridge of surface probability with triangles scaled to match the local discretization of space given by the algorithm, we present results from 3D data generated by scanning lidar and structure from motion.

3D data fusion multiresolution surface generation ↗

NASA NTRSDate not supplied

In-Situ Process Monitoring, Synchronization, and Mapping Laser Powder Bed Fusion Builds of Ti6Al4V

The use of in-situ process monitoring is of interest to lower the cost of inspection for the qualification of laser powder bed fusion (LPBF) parts. Precise monitoring of the LPBF-AM build process constitutes a multi-scale and multi-discipline task. There are several significant challenges to the in-situ approach: the synchronization of sensor signals to process steps, the physical interpretation and classification of sensor signals, managing very large datasets, and comparing the inputs with the observed monitoring signals. At NASA Langley Research Center, a configurable architecture additive testbed has been developed to monitor the build process with synchronized sensors. The philosophy and method adopted for the synchronization of the cameras with laser power & position Ti-6Al-4V LPBF are described. The synchronized in-situ monitoring signals are compared with ex-situ nondestructive inspection and optical microscopy observations. Such comparisons permit a better understanding of how the sequential process actions of LPBF-AM can affect build quality.

Laser Powder Bed Fusion↗