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Results for “quality inspection”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

A New Simultaneous Membrane Thickness and Catalyst Loading Measurement for Fuel Cell Proton-Exchange Assemblies by $\mathrm{IR}$ Transmission

Here, we present a study of mid-infrared (mid-IR) transmission through typical proton-exchange fuel cell and water electrolyzer catalyst-coated membrane materials, and the determination of membrane layer thickness, and catalyst layer loading, from the power of the transmitted beam. Measured membrane thicknesses lay in the range of 25-125 um, and catalyst areal loadings range from 0.05 to 0.35 mg/cm 2 . We show that the transmission spectrum correlated to membrane thickness and catalyst loading values separately, and also used a mathematical model to calculate both quantities simultaneously, from a single measurement of transmission. Measurements were carried out using a Fourier-transform infrared (FTIR) spectrometer, in specular transmission mode, in the wavelength range of 3-13 um (3333-770 cm -1 ). We discuss the potential application of this method to the development of roll-to-roll manufacturing full-area-scanning quality inspection of catalyst-coated membrane (CCM) materials.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2026

Modeling the PV System Level Economic Impact of PV Connector Failure Modes

Photovoltaic (PV) connectors must maintain mechanical integrity for over 25 years while operating under UV exposure, elevated temperature, and mechanical loading. Connector degradation increases with electrical resistance, leading to energy losses, unplanned downtime, and higher operation and maintenance (O&M) costs and in severe cases, safety risks from overhearing or arcing. Connector related failures remain among the most frequent causes of disruption in utility-scale PV (UPV) systems, yet their lifetime economic impacts are poorly quantified. This work presents a techno-economic analysis (TEA) framework that links identified connector failure modes to system level energy losses and lifetime cost impacts using identified resistance measurements and failure rates from 6,2761 PV connectors inspected. Connector failures increase system level O&M costs, raising LCOE by roughly 5%. Downtime driven availability losses dominate economic impact. Resistance-driven I2R and IV-curve losses are secondary, but remain non-negligible. Thermal damage, bend-radius violations, and loose connections drive the majority of LCOE uplift Improving connector reliability through better installation quality, inspection, and design can meaningfully reduce lost energy, O&M costs, and LCOE.

14 SOLAR ENERGY↗
DOE OSTI2021

Rapid Quality Assessment in Additive Manufacturing: New Procedure Accelerates Build Quality Assessment. White paper

Accelerated growth of the additive manufacturing (AM) industry in recent years is accompanied by a rising need for methods to quickly assess quality at-scale. Current practices for quality inspection include nondestructive test methods and destructive testing of witness coupons, which are artifacts built alongside the actual part. However, these methods can be costly and time-consuming. Recognizing this need, the Additive Manufacturing Center of Excellence (AM CoE) initiated a project led by its partner, Auburn University, to develop rapid testing procedure using asbuilt samples tested in torsion to quantitatively assess build quality. The presented work developed a rapid testing procedure using as-built samples tested in torsion to quantify small variances for assessing build quality.

42 ENGINEERING↗
DOE OSTI2021

Acoustic Steady-State Excitation Spatial Spectroscopy (ASSESS)

Safely launching and landing spacecraft, especially reusable spacecraft, requires detailed inspections of the launch vehicle to identify potential manufacturing and service-induced flaws. As an automated full-structure ultrasonic scanning technology, Acoustic Steady-State Excitation Spatial Spectroscopy (ASSESS) can rapidly and non-intrusively detect a wide variety of defects in applications where identifying subtle flaws is paramount. ASSESS is a non-destructive evaluation technology that leverages continuous excitation and laser Doppler vibrometry to make fast, high-quality inspections at stand-off distances. The ASSESS technology has undergone extensive laboratory testing and several field tests specific to oil and gas and additive manufacturing applications. We seek a commercialization partner to fund aerospace application-specific R&D and product development through a Cooperative Research and Development Agreement (CRADA).

42 ENGINEERING↗
NASA NTRS2005

Optically Stimulated Electron Emission Contamination Monitor and Method

An apparatus and method for performing quality inspections on a test surface based on optically stimulated emission of electrons. In one embodiment, the apparatus comprises a device for producing optical radiation having a plurality of different spectrum lines, selecting at least one of the spectrum lines, and directing the selected spectrum line to the test surface, and circuitry for detecting a current of photoelectrons emitted from the test surface, generating a signal indicative of photoelectron current, and for indicating a condition of quality based on the generated signal indicative of the photoelectron current. In one embodiment, the method comprises producing optical radiation having a plurality of different spectrum lines, selecting at least one of the spectrum lines and directing the selected spectrum line to the test surface, detecting a current of photoelectrons emitted from the test surface and generating a signal indicative of photoelectron current, and indicating a condition of quality based on the generated signal indicative of the photoelectron current.

Christopher S Welch↗
DOE OSTI2024

Leverage modern artificial intelligence (AI) enabled systems for waste reduction

Manufacturing industries continue to face challenges in reducing waste, as upstream strategies such as source reduction and product redesign require a deeper understanding of processes compared to conventional recycling methods. Recent advancements in artificial intelligence (AI) and machine learning (ML) have opened new opportunities to integrate modern computational techniques with traditional waste minimization strategies. This paper explores AI-enabled approaches for product redesign, source reduction, and recycling that can significantly reduce waste generation while improving efficiency and sustainability. AI-driven material substitution and lightweighting in product design enable discovery of novel materials with optimized properties, reducing waste without compromising performance. Reinforcement learning models optimize process parameters, raw material specifications, and machine sequencing to minimize production losses, while Industrial Internet of Things (IIoT) systems paired with AI analytics enhance real-time waste tracking, predictive maintenance, and quality inspection. Furthermore, AI-based demand forecasting and production planning reduce overproduction and excess inventory, as demonstrated in industrial applications. In recycling, ML-powered pattern recognition and robotic sorting technologies achieve higher accuracy in waste segregation, directly improving recycling efficiency. Complementary solutions such as smart bins and AI-enabled waste pickup scheduling optimize collection logistics, reducing both costs and emissions. Although implementation requires upfront investment in infrastructure and training, the long-term benefits include higher material efficiency, reduced waste, improved product quality, and stronger sustainability outcomes across the supply chain. By leveraging AI-enabled systems, manufacturers can align waste minimization efforts with circular economy principles, creating scalable solutions for both industry and society.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

Laser calibration of the ATLAS Tile Calorimeter during LHC Run 2

This article reports the laser calibration of the hadronic Tile Calorimeter of the ATLAS experiment in the LHC Run 2 data campaign. The upgraded Laser II calibration system is described. The system was commissioned during the first LHC Long Shutdown, exhibiting a stability better than 0.8% for the laser light monitoring. The methods employed to derive the detector calibration factors with data from the laser calibration runs are also detailed. These allowed to correct for the response fluctuations of the 9852 photomultiplier tubes of the Tile Calorimeter with a total uncertainty of 0.5% plus a luminosity-dependent sub-dominant term. Finally, we report the regular monitoring and performance studies using laser events in both standalone runs and during proton collisions. These studies include channel timing and quality inspection, and photomultiplier linearity and response dependence on anode current.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2024

Ensemble Manufacturing Techniques for Steam Turbine Components Across Length Scales

Faster design to manufacturing requirements were sought for steam turbine components to meet the changing demands of today’s power grid of improved efficiency through operating temperature increases and enhanced operational flexibility from baseload to cyclic operations. Advances in multiple advanced manufacturing (AM) process enabled redesign of turbine components for extreme environments with the potential to reduce cost. AM is of particular interest to improve component functionality, higher temperature capability, and superior durability in large scale steam turbine applications. AM methods have an immense potential to open-up the design space by working directly with the 3D model to produce near-net shapes, enable fast design-manufacturing iterations, thereby significantly reducing product cost and lead-time up to 25 % from current baseline. However, these benefits cannot be fully realized due to the potential for unknown AM processing defects and their resultant effect upon component performance in service. Siemens is partnering with Oak Ridge National Laboratory (ORNL), Electric Power Research Institute (EPRI), and Connecticut Center for Advanced Technology (CCAT) to advance the knowledge of complex process-material interactions for desired microstructures and properties that are closely interlinked to component geometries across different length scales. The proposed program utilized an ensemble of multidisciplinary technologies to accelerate the development of materials, high-throughput experiments for their qualification, and design flexibility/topology optimization for repair/redesign of components to address critical failure mechanisms for improved performance and increased reliability of existing power plant components. The proposed activities, if successfully demonstrated for identified components, will enable paradigm shift in customized manufacturing and accelerated qualification/certification towards increased steam turbine component durability, increased turbine efficiency, and reduced CO 2 emissions in load-following environments compared to today’s technology. Technology maturation is built into the project as successful research will include customized process-component down-selection enabling AM methodologies to be incorporated directly into the existing supply chain. The specific activities of the proposed effort are: 1. Topology optimization of down-selected steam turbine parts that are amenable to additive and hybrid manufacturing for cost/performance improvement. 2. Process-structure-property relationships for five AM processes for steam turbine materials of interest to compare with conventional materials. 3. Perform part/assembly build process using advanced additive/hybrid machine tools followed by quality inspection of the built components for insight into qualification for production scale-up. Steam turbine rig testing of printed components under targeted, well monitored and characterized environmental conditions of for performance comparison of baseline and redesigned components.

36 MATERIALS SCIENCE↗
NASA NTRS1998

Method Developed for the High-Temperature Nondestructive Evaluation of Fiber-Reinforced Silicon Carbide Ceramic Matrix Composites

Ceramic matrix composites have emerged as candidate materials to allow higher operating temperatures (1000 to 1400 C) in gas turbine engines. A need, therefore, exists to develop nondestructive methods to evaluate material integrity at the material operating temperature by monitoring thermal and mechanical fatigue. These methods would also have potential as quality inspection tools. The goal of this investigation at the NASA Lewis Research Center is to survey and correlate the temperature-dependent damping and stiffness of advanced ceramic composite materials with imposed thermal and stress histories that simulate in-service turbine engine conditions. A typical sample size of 100 by 4 by 2 cubic millimeters, along with the specified stiffness and density, placed the fundamental vibration frequencies between 100 and 2000 Hz. A modified Forster apparatus seemed most applicable to simultaneously measure both damping and stiffness. Testing in vacuum reduced the effects of air on the measurements. In this method, a single composite sample is vibrated at its fundamental tone; then suddenly, the mechanical excitation is removed so that the sample's motion freely decays with time. Typical results are illlustrated in this paper.

Goldsby, Jon C.↗
DOE OSTI2024

01-06 DOME Construction Project

Construction Subcontract award to ESTECH - Aug 23 Partial Notice to Proceed for ESTECH mobilization - Sept 23 Final NTP for full construction activities - Oct 23. Quality Inspection Support awarded to ATLAS - Feb 24 Request for Proposal to award a Commissioning Agent subcontract issued - Apr 24 Construction activities projected completion - Jun 25

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
NASA NTRS1968

Inspection criteria ensure quality control of parallel gap soldering

Investigation of parallel gap soldering of electrical leads resulted in recommendation on material preparation, equipment, process control, and visual inspection criteria to ensure reliable solder joints. The recommendations will minimize problems in heat-dwell time, amount of solder, bridging conductors, and damage of circuitry.

Burka, J. A.↗
NASA NTRS2011

Source Inspection Scheduling Calendar

Quality is an essential component for creating flight hardware travelling through space since the hardware is extremely expensive and cannot be reworked or repaired once launched. An important step in this process is ensuring the quality of hardware procured from Jet Propulsion Laboratory's (JPL) suppliers. An important element of determining supplier quality is source inspection. Source inspections are performed at suppliers' facilities by JPL employeesto ensure that hardware characteristics are acceptable before being covered up and/or delivered to JPL.

quality assurance↗
NASA NTRS1983

Quality-Planning-Requirements Documents

Report outlines planning procedures used in establishing inspection and quality assurance activities required of contractors constructing and testing Space Shuttle and ground-support equipment. Report useful to contractors establishing inspection points in commercial manufacturing operations.

Leonard, P. A.↗
NASA NTRS2009

Compliance with Aerospace Quality Assurance Standard AS9100

The contents include: 1) United States Federal Acquisition Regulations (FAR) Part 46, Quality Assurance; 2) NASA Quality Roadmap; 3) AS9003 Inspection and Test Quality Management System; 4) Government Oversight Responsibilities; and 5) Third Party vs Second Party Oversight.

Hughitt, Brian↗
NASA NTRS1997

Software Design Improvements: Software Quality and the Design and Inspection Process - Part 2

The application of assurance engineering techniques improves the duration of failure-free performance of software. The totality of features and characteristics of a software product are what determine its ability to satisfy customer needs. Software in safety-critical systems is very important to NASA. We follow the System Safety Working Groups definition for system safety software as: 'The optimization of system safety in the design, development, use and maintenance of software and its integration with safety-critical systems in an operational environment. 'If it is not safe, say so' has become our motto. This paper goes over methods that have been used by NASA to make software design improvements by focusing on software quality and the design and inspection process.

Lalli, Vincent R.↗
DOE OSTI2025

Prelude to Simulation Diagnostics in MOOSE: Diagnosing Meshes

As finite element simulations increase in complexity, so does the need for high quality meshes. Without proper diagnostics, issues pertaining to poor mesh quality or improper mesh construction may go undetected, causing simulations to fail unexpectedly. This paper details the new mesh diagnostic system available in MOOSE, which provides users with the tools to inspect mesh quality for both externally and internally generated meshes. This system can detect issues arising from element volume size, non-conformal elements, intersecting edges, missing sidesets, as well as other common mesh issues. As meshes increase in size and complexity, such issues become more difficult to diagnose through visual inspection alone.

99 - GENERAL AND MISCELLANEOUS↗