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At least 361 records · Page 20

Intern Poster Session 08/13: Autonomous Nuclear Robotics: Applications in nuclear waste inspection and hot cell experiments

The nuclear industry is experiencing renewed interest in autonomous robotics, yet most deployed systems remain teleoperated with limited autonomy. This work presents two contributions toward fully autonomous nuclear robotic systems: autonomous waste inspection at the Hanford Site and an autonomous hot cell laboratory framework. Inspections of Hanford's underground waste storage tanks are performed manually at significant cost and personnel exposure. We developed a reinforcement-learning (RL) training pipeline for a custom-built inspection arm. In parallel, we are designing an autonomous laboratory framework for post-irradiation examination in hot cells at the Specimen Preparation Laboratory (SPL) that integrates computer vision, task and motion planning, hardware execution, and operator-in-the-loop control. These systems demonstrate a path toward safer, more efficient nuclear operations by reducing human exposure while maintaining rigorous human oversight at critical decision points.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NDE Technology Development Program for Non-Visual Volumetric Inspection Technology; Sensor Effectiveness Testing Report

The Pacific Northwest National Laboratory (PNNL) located in Richland, Washington, hosted and administered Sensor Effectiveness Testing that allowed four different participants to demonstrate the NDE volumetric inspection technologies that were previously demonstrated during the Technology Screening session. This document provides a Sensor Effectiveness Testing report for the final part of Phase I of a three-phase NDE Technology Development Program designed to identify and mature a system or set of non-visual volumetric NDE technologies for Hanford DST primary liner bottom inspection. Phase I of the program will baseline the performance of current or emerging non-visual volumetric NDE technologies for their ability to detect and characterize primary liner bottom flaws, and identify candidate technologies for adaptation and maturation for Phase II of the program.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

NDE Technology Development Program for Non-Visual Volumetric Inspection Technology: Technology Screening Report

The Pacific Northwest National Laboratory (PNNL) located in Richland, Washington, hosted and administered a Technology Screening test that allowed four different participants to demonstrate the NDE volumetric inspection technologies that were proposed in response to the WRPS EOI. This document provides a Technology Screening test report for the initial part of Phase I of a three-phase NDE Technology Development Program designed to identify and mature a system or set of non-visual volumetric NDE technologies for Hanford DST primary liner bottom inspection. Phase I of the program will baseline the performance of current or emerging non-visual volumetric NDE technologies for their ability to detect and characterize primary liner bottom flaws, and identify candidate technologies for adaptation and maturation for Phase II of the program.

42 ENGINEERING↗

Study on the ultrasonic inspection method using the full matrix capture for the in service railway wheel

The quality of wheel is especially important for the safety of high speed railway. In this paper, a new ultrasonic array inspection method, the Full Matrix Capture (FMC) has been studied and applied to the high speed railway wheel inspection, especially in the wheel web from the tread. Firstly, the principle of FMC and TFM algorithm is discussed, and then the new optimization is applied to the standard FMC; Secondly the fundamentals of optimization is described in detail and the performance is analyzed. Finally, the experiment has been built with a standard phased array block and railway wheel, and then the testing results are discussed and analyzed. It is demonstrated that this change for the ultrasonic data acquisition and image reconstruction has higher efficiency and lower cost comparing to the FMC's procedure.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

Laser-ultrasonic inspection of hybrid laser-arc welded HSLA-65 steel

The hybrid laser-arc welding (HLAW) process is a relatively low heat input joining technology that combines the synergistic qualities of both the high energy density laser beam for deep penetration and the arc for wide fit-up gap tolerance. This process is especially suitable for the shipbuilding industry where thick-gauge section, long steel plates have been widely used in a butt joint configuration. In this study, preliminary exploration was carried out to detect and visualize the welding defects using laser ultrasonics combined with the synthetic aperture focusing technique (SAFT). Results obtained on 9.3 mm thick butt-welded HSLA-65 steel plates indicated that the laser-ultrasonic SAFT inspection technique can successfully detect and visualize the presence of porosity, lack of fusion and internal crack defects. This was further confirmed by X-ray digital radiography and metallography. The results obtained clearly show the potential of using the laser-ultrasonic technology for the automated inspection of hybrid laser-arc welds.

36 MATERIALS SCIENCE↗

Development of electromagnetic acoustic transducer (EMAT) phased arrays for SFR inspection

A long-standing problem for Sodium cooled Fast Reactor (SFR) instrumentation is the development of efficient under-sodium visualization systems adapted to the hot and opaque sodium environment. Electromagnetic Acoustic Transducers (EMAT) are potential candidates for a new generation of Ultrasonic Testing (UT) probes well-suited for SFR inspection that can overcome drawbacks of classical piezoelectric probes in sodium environment. Based on the use of new CIVA simulation tools, we have designed and optimized an advanced EMAT probe for under-sodium visualization. This has led to the development of a fully functional L-wave EMAT sensing system composed of 8 elements and a casing withstanding 200° C sodium inspection. Laboratory experiments demonstrated the probe's ability to sweep an ultrasonic beam to an angle of 15 degrees. Testing in a specialized sodium facility has shown that it was possible to obtain pulse-echo signals from a target under several different angles from a fixed position.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

An automated miniature robotic vehicle inspection system

A novel, autonomous reconfigurable robotic inspection system for quantitative NDE mapping is presented. The system consists of a fleet of wireless (802.11g) miniature robotic vehicles, each approximately 175 × 125 × 85 mm with magnetic wheels that enable them to inspect industrial structures such as storage tanks, chimneys and large diameter pipe work. The robots carry one of a number of payloads including a two channel MFL sensor, a 5 MHz dry coupled UT thickness wheel probe and a machine vision camera that images the surface. The system creates an NDE map of the structure overlaying results onto a 3D model in real time. The authors provide an overview of the robot design, data fusion algorithms (positioning and NDE) and visualization software.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

Modelling NDE pulse-echo inspection of misorientated planar rough defects using an elastic finite element method

Pulse-echo ultrasonic NDE examination of large pressure vessel forgings is a design and construction code requirement in the power generation industry. Such inspections aim to size and characterise potential defects that may have formed during the forging process. Typically these defects have a range of orientations and surface roughnesses which can greatly affect ultrasonic wave scattering behaviour. Ultrasonic modelling techniques can provide insight into defect response and therefore aid in characterisation. However, analytical approaches to solving these scattering problems can become inaccurate, especially when applied to increasingly complex defect geometries. To overcome these limitations a elastic Finite Element (FE) method has been developed to simulate pulse-echo inspections of embedded planar defects. The FE model comprises a significantly reduced spatial domain allowing for a Monte-Carlo based approach to consider multiple realisations of defect orientation and surface roughness. The results confirm that defects aligned perpendicular to the path of beam propagation attenuate ultrasonic signals according to the level of surface roughness. However, for defects orientated away from this plane, surface roughness can increase the magnitude of the scattered component propagating back along the path of the incident beam. This study therefore highlights instances where defect roughness increases the magnitude of ultrasonic scattered signals, as opposed to attenuation which is more often assumed.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

Mixture-of-Experts for Multi-Domain Defect Identification in Non-Destructive Inspection

Composite materials are widely used in aircraft structures because of their superior mechanical properties. However, their complex failure modes require sophisticated inspection methods to ensure structural integrity. Ultrasonic testing (UT) is a common non-destructive inspection (NDI) technique for aircraft composites that can detect internal and external defects with high resolution and accuracy. Despite their effectiveness, traditional UT methods rely on the manual interpretation of ultrasonic signals, which is time-consuming, labor-intensive, and subjective. Furthermore, processing such large-scale data, particularly across materials of varying thicknesses, significantly increases the computational demands of deep learning model optimization. To overcome these challenges, we propose an efficient sparse mixture-of-experts (MoE) model with a multi-level loss function and introduce four novel training objectives to improve computational efficiency and accuracy in identifying surface defects in composite aircraft materials. Here, we evaluated our approach on material with multiple thicknesses or domains comprising various defects. Our experimental results demonstrate higher accuracy and F1-Score, with only 10% training epochs compared to baseline MoE.

composite materials↗

Lighting Studies for Fuelling Machine Deployed Visual Inspection Tool

Under subcontract to James Fisher Nuclear, Ltd., INL has been reviewing advanced vision systems for inspection of graphite in high radiation, high temperature, and high pressure environments. INL has performed calculations and proof-of-principle measurements of optics and lighting techniques to be considered for visual inspection of graphite fuel channels in AGR reactors in UK.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

The Post-Closure Inspection Report For Closed Non- Resource Conservation And Recovery Act (RCRA) Corrective Action Units (CAUs) On The Nevada National Security Site (NNSS), For Calendar Year 2018

This letter serves as the Calendar Year 2018 post-closure inspection letter report for the following Non-RCRA CAUs located on the NNSS, including CAUs located on the Nevada Test and Training Range (NTTR) that are accessed through the NNSS Main Gate. Use restriction issues that were identified in the 2017 inspections were addressed in 2018.

54 ENVIRONMENTAL SCIENCES↗

Collaboration on SBIR/TTO Phase II Project for Optical QC Device and Collaboration on SBIR/TTO Phase II-b Project for Advanced Quality Inspection Device Development: Cooperative Research and Development CRADA Number CRD-16-00652 (Final Report)

The overall goal of this program is to develop and commercialize a turnkey quality control solution for the entire PEM fuel cell manufacturing process including membrane, gas diffusion layers, catalyst, and assembled systems. This quality control solution is unique to each customer’s specific needs but includes a suite of in-line quality control systems for roll-to-roll manufacturing that can target thin, transparent membrane as well as opaque membrane, catalyst, and GDLs. The Phase II developed the CPNUVV system for thin, transparent membrane that operates using polarized filters to enhance defect resolution and determine thickness. However, PEM material manufacturers want a complete, turnkey solution for all components of the PEM fuel cell. In the Phase IIB, Mainstream will partner with NREL, and transition reflectance technology NREL developed (US Patent 9,234,843) to operate in real-time on a web-line to develop a total solution to PEM quality control. The device will identify and mark defects as well as monitor materials thickness in real-time to improve line efficiency and to reduce waste. The research performed at NREL under this CRADA increases the basis of knowledge about optical inspection methods, how they perform with regards to fuel cell component materials, and how they can be implemented in in-line, real-time configurations to provide quality inspection for roll-to-roll (R2R) manufacturing. Methods explored were found to be sensitive to catalyst loading in electrodes on both membrane and gas diffusion media substrates and to membrane thickness, across a broad range of thickness. The latter capability is novel and now patented and provides a previously unstudied and undemonstrated capability for R2R manufacturing of membranes.

30 DIRECT ENERGY CONVERSION↗

Framework and Tool for Artificial Intelligence & Machine Learning (AI/ML) Enabled Automated Non-Destructive Inspection of Composites Aerostructures Manufacturing

Vehicles and systems in the field of aerospace have two major requirements: a high demand for a large quantity and an expectation to perform for their lifetime with little to no failures. Thus, there is a need for a fast production rate of aerospace products with high quality. Improvements to production rate have many benefits, including a reduction in energy consumption per unit manufactured. This would be from factory energy usage, which is required to build and verify a product. Manufacturing process specifications require inspection of parts to determine if any flaws are present. Depending on factory planning and product quality, especially at higher rates, the evaluation process can pose a production rate bottleneck. This project was comprised of using artificial intelligence and machine learning (AI/ML) methods on inspection evaluations with the objective of reducing the required time to produce an aerospace structure or product and without reducing the final quality.

42 ENGINEERING↗

Formal Inspection: A Tool for TQM

The goal of the Formal Inspection Program at the Jet Propulsion Laboratory (JPL) is to support projects wishing to use Formal Inspections to improve the quality of software and system level engineering products.

errors total quality↗

Visual and x-ray inspection characteristics of eutectic and lead free assemblies

For high reliability applications, visual inspection has been the key technique for most conventional electronic package assemblies. Now, the use of x-ray technique has become an additional inspection requirement for quality control and detection of unique defects due to manufacturing of advanced electronic array packages such as ball grid array (BGAs) and chip scale packages (CSPs).

x-ray↗