Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Sensor”

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 397 records · Page 22
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

REFRACTORY COMPACT HEAT EXCHANGERS WITH EMBEDDED SENSORS ENABLED BY HYBRID ADVANCED SINTERING AND ADDITIVE APPROACH

Structural health monitoring (SHM) of compact heat exchangers (CHXs) operating in extreme environments is essential for ensuring system reliability, safety, and longevity. This study presents the development of high-temperature sensors fabricated via aerosol jet printing (AJP) using platinum ink, selected for its exceptional thermal stability, oxidation resistance, and electrical conductivity. AJP enables precise deposition of fine-feature sensor patterns onto complex geometries, making it well-suited for integration within CHX architectures. To enhance sensor durability, an alumina-based ceramic protective layer was printed over the platinum sensing elements. The sensors demonstrated stable, repeatable performance up to 900?°C during extended thermal cycling. A custom test setup was developed to evaluate sensor accuracy and robustness under steady-state and transient conditions. Substrate screening identified HG-1 ceramic-coated stainless steel as the most effective platform, offering strong adhesion and low resistance. Furthermore, electric field-assisted sintering (EFAS) was employed to embed the sensors into stainless steel 316L matrices without degrading their functionality. Post-embedding electrical tests confirmed sensor integrity, and initial characterization suggests strong potential for in-situ monitoring. This work provides a scalable strategy for integrating high-performance temperature sensors directly into refractory components, advancing embedded SHM technologies for harsh operating environments.

36 - MATERIALS SCIENCE↗
DOE OSTI2022

Low-Power, Flexible Sensor Arrays with Solderless Board-to-Board Connectors for Monitoring Soil Deformation and Temperature

Landslides are a global and frequent natural hazard, affecting many communities and infrastructure networks. Technological solutions are needed for long-term, large-scale condition monitoring of infrastructure earthworks or natural slopes. However, current instruments for slope stability monitoring are often costly, require a complex installation process and/or data processing schemes, or have poor resolution. Wireless sensor networks comprising low-power, low-cost sensors have been shown to be a crucial part of landslide early warning systems. Here, we present the development of a novel sensing approach that uses linear arrays of three-axis accelerometers for monitoring changes in sensor inclination, and thus the surrounding soil’s deformation. By combining these deformation measurements with depth-resolved temperature measurements, we can link our data to subsurface thermal–hydrological regimes where relevant. In this research, we present a configuration of cascaded I2C sensors that (i) have ultra-low power consumption and (ii) enable an adjustable probe length. From an electromechanical perspective, we developed a novel board-to-board connection method that enables narrow, semi-flexible sensor arrays and a streamlined assembly process. The low-cost connection method relies on a specific FR4 printed circuit board design that allows board-to-board press fitting without using electromechanical components or solder connections. The sensor assembly is placed in a thin, semi-flexible tube (inner diameter 6.35 mm) that is filled with an epoxy compound. The resulting sensor probe is connected to an AA-battery-powered data logger with wireless connectivity. We characterize the system’s electromechanical properties and investigate the accuracy of deformation measurements. Our experiments, performed with probes up to 1.8 m long, demonstrate long-term connector stability, as well as probe mechanical flexibility. Furthermore, our accuracy analysis indicates that deformation measurements can be performed with a 0.390 mm resolution and a 95% confidence interval of ±0.73 mm per meter of probe length. This research shows the suitability of low-cost accelerometer arrays for distributed soil stability monitoring. In comparison with emerging low-cost measurements of surface displacement, our approach provides depth-resolved deformation, which can inform about shallow sliding surfaces.

deformation monitoring↗
DOE OSTI2024

Calculating a minimum overlap period for successful intercalibration of soil moisture sensors

Abstract Long‐term in situ soil moisture monitoring inevitably requires sensors to be replaced. Ensuing discontinuities in the data record can be mitigated by intercalibration, however it is unclear how long the existing sensor needs to remain alongside the newly installed before there is enough overlapping data to generate a robust intercalibration. We used 154 pairs of established and newly installed sensors within the Marena, Oklahoma, In Situ Sensor Testbed to determine if there is a minimum overlap time that should be considered when planning upcoming replacements. Hourly observations of the existing sensor were linearly calibrated to those of the newly installed sensor with coefficients determined from overlap periods incremented by 30 days until a reference period of 2 years was reached. The resulting bias, root‐mean‐square error, and correlation coefficient for sensor pairs indicate that a minimum of 6 to 9 months of overlapping data are required to generate a successful intercalibration. Extending that to a full year before decommissioning the old sensor results in a stable intercalibration with higher confidence.

Agriculture↗
DOE OSTI2024

Low-cost sensor-based damage localization for large-area monitoring of FRP composites

Abstract In recent years, there has been growing interest in self-sensing structural materials across research and industry sectors. Detecting and locating structural damage typically requires numerous sensors wired to a data acquisition (DAQ) circuit, rendering implementation impractical in real structures. This paper proposes an innovative, cost-effective sensor network for damage detection and localization in fiber-reinforced polymer composites. The innovation encompasses three key elements: (1) utilizing carbon fiber tows within the composite as piezoresistive sensors, eliminating the need for additional foreign sensor devices; (2) introducing a novel sensor layout wherein sensor tow branches with varied resistance values are connected in parallel, reducing the number of connections to the DAQ circuit and cutting manufacturing costs significantly; (3) developing a practical sensor terminal fabrication technique to minimize manufacturing expenses. The proposed design methodology for the branch resistance values is first validated using a demonstration panel. Subsequently, the overall strategy is assessed by conducting impact tests on carbon and glass fiber-reinforced composite specimens. Results validate the sensor’s ability to accurately detect and locate structural damage.

Demo, Luke B. (ORCID:0000000208806522)↗
DOE OSTI2019

Direct-Write Printed Current Sensor for Load Monitoring Applications

We report on a flexible current sensor development employing direct-write printing and additive manufacturing techniques. The integrated current sensor unit incorporates sensing, data processing & storage, and in-field calibration capabilities. A combination of direct-write printing technique and low-temperature curable metallic ink is used to print Ag wires around a 12.5-μm -thick permalloy film. The overall thickness of the polyimide substrate and permalloy sheet remains well-below 500 μm enabling wrap-around sensor functionality. Fused deposition modeling (FDM) additive manufacturing is used to build custom parts for sensor mounting, encapsulation, and an in-field calibration unit using heat and chemical-resistant thermoplastic which responds well to mechanical stress. In the present configuration, the integrated current sensor unit can be powered through USB or 4 AAA batteries to allow data collection and sensor calibration in the field. The flexible current sensor employing a continuous sheet of the permalloy exhibited a well-behaved signal output response at peak current levels exceeding 15A and in the applied ac frequency range of 60 Hz–10 kHz. Overall, the combination of direct-write printing, thin permalloy material, and additive manufacturing technique shows promise for the development of a reconfigurable low-cost current sensor that can be deployed in large numbers at locations of interest to avail the cost and energy-saving opportunities in industrial/commercial and residential applications.

Yu, Yongchao↗
DOE OSTI2023

A bacterial sensor taxonomy across earth ecosystems for machine learning applications

Microbial communities have evolved to colonize all ecosystems of the planet, from the deep sea to the human gut. Microbes survive by sensing, responding, and adapting to immediate environmental cues. This process is driven by signal transduction proteins such as histidine kinases, which use their sensing domains to bind or otherwise detect environmental cues and “transduce” signals to adjust internal processes. We hypothesized that an ecosystem’s unique stimuli leave a sensor “fingerprint,” able to identify and shed insight on ecosystem conditions. To test this, we collected 20,712 publicly available metagenomes from Host-associated, Environmental, and Engineered ecosystems across the globe. We extracted and clustered the collection’s nearly 18M unique sensory domains into 113,712 similar groupings with MMseqs2. We built gradient-boosted decision tree machine learning models and found we could classify the ecosystem type (accuracy: 87%) and predict the levels of different physical parameters (R2 score: 83%) using the sensor cluster abundance as features. Feature importance enables identification of the most predictive sensors to differentiate between ecosystems which can lead to mechanistic interpretations if the sensor domains are well annotated. To demonstrate this, a machine learning model was trained to predict patient’s disease state and used to identify domains related to oxygen sensing present in a healthy gut but missing in patients with abnormal conditions. Moreover, since 98.7% of identified sensor domains are uncharacterized, importance ranking can be used to prioritize sensors to determine what ecosystem function they may be sensing. Furthermore, these new predictive sensors can function as targets for novel sensor engineering with applications in biotechnology, ecosystem maintenance, and medicine.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2023

Parameter Estimation for Decoding Sensor Signals

This paper introduces a parameter estimation approach for decoding digital sensor signals in a cyber-physical system. For unknown or not fully characterized digital sensor data, it can be difficult to decipher a desired signal from background or noise. In a cyber-physical system with networked sensors, we can leverage knowledge of the physical system to inform the decoding of the digital signals. This work in progress is a case study on deciphering commercial vehicle on-board sensor networks that communicate through the Controller Area Network (CAN). By understanding the stock vehicle sensor network, a vehicle can be extended into a scalable research platform with minimal instrumentation. Our challenge was to localize desired sensor signals encoded in network traffic that included other sensor data, control messages, as well as encoding and security overhead. Due to the vehicle’s unknown sensor network, our approach developed methods to efficiently analyze and identify key signals despite the large state-space for potential signal embeddings.

Nice, Matthew↗
DOE OSTI2023

Signal Processing of Multiplexed Optical PWM Signals for Sensor Arrays in Nuclear Environments

Safe and effective generation of terrestrial nuclear power greatly benefits from the actionable data provided by the array of sensors located throughout a plant to provide a holistic online indication of reactor operation. This array includes sensors for monitoring coolant flow and pressure, temperature and heat transfer, radiation levels, structure health monitoring, and other critical parameters for reactor operation. While sensors capable of measuring these parameters have been developed, the electronics used in the pre-amplification and analog-to-digital conversion of the small signals they produce are extremely sensitive and susceptible to damage by high-temperatures and radiation environments nuclear reactors encounter while generating power. The small signals from sensors in nuclear power plants (NPPs) are transmitted over long cable runs which introduce dispersion artifacts into the signals of interest as well as electromagnetic interference (EMI) from lighting fixtures, pumps, mains electricity, and other equipment. To overcome these challenges, a front-end digitization (FREND) platform has been developed to use radiation-tolerant electronics to multiplex, amplify, and optically encode signals from an array of sensors for transmission over an optical fiber to mitigate dispersion and EMI artifacts from long runs of electrical cabling. To recover the optically transmitted data, a signal processing scheme based on 1-dimensional template matching to an indexing channel is described herein and demonstrated to have an effective bit-depth of 9.2 bits (1%). This scheme has been validated in proof-of-concept, non-nuclear testing and preliminary experimental results show good agreement between the measured optical output and and sensor input signals. The FREND system represents a low-loss data link between sensors in nuclear environments and data acquisition hardware which is aimed at improving the signal-to-noise ratio of the data acquired from these sensors to provide better information to operators and researchers.

Sweeney, Dan↗
DOE OSTI2024

Four-channel optically pumped magnetometer for a magnetoencephalography sensor array

We present a novel four-channel optically pumped magnetometer (OPM) for magnetoencephalography that utilizes a two-color pump/probe scheme on a single optical axis. We characterize its performance across 18 built sensor modules. The new sensor implements several improvements over our previously developed sensor including lower vapor-cell operating temperature, improved probe-light detection optics, and reduced optical power requirements. The sensor also has new electromagnetic field coils on the sensor head which are designed using stream-function-based current optimization. We detail the coil design methodology and present experimental characterization of the coil performance. The magnetic sensitivity of the sensor is on average 12.3 fT/rt-Hz across the 18 modules while the average gradiometrically inferred sensitivity is about 6.0 fT/rt-Hz. The sensor 3-dB bandwidth is 100 Hz on average. The on-sensor coil performance is in good agreement with the simulations.

Iivanainen, Joonas (ORCID:0000000160344604)↗
DOE OSTI2022

Spatial Study 2021: Sensor-Based Time Series of Surface Water Temperature, Specific Conductance, Total Dissolved Solids, pH, and Dissolved Oxygen from across Multiple Watersheds in the Yakima River Basin, Washington, USA (v3)

This dataset supports a broader study examining the drivers of spatial variability in sediment respiration rates in the Yakima River Basin. The dataset provides two-hour time series hydrological and water chemistry sensor data, manual chamber open channel respiration data, handheld sensor water chemistry data, river substrate grain size photos, general environmental context photos, and field metadata (including qualitative information on instream and river corridor characteristics) collected during the same two-week period at 47 sites within multiple rivers throughout the Yakima River Basin in Washington, USA. Grain size photos can be used to improve estimates of channel substrate D50 data. Related sample-based water chemistry data are published separately at https://data.ess-dive.lbl.gov/datasets/doi:10.15485/1898914.This dataset is comprised of four main folders, one containing three sensor-specific subfolders and the others containing photographs. The SFA_SpatialStudy_2021_SensorData main data folder includes file-level metadata (FLMD), data dictionary (dd), installation methods, field metadata, Ultrameter water chemistry data, field data collection protocols, international generic sample number (IGSN) mapping file, and a readme file. The “Sensor_Manual_Specifications” subfolder contains pdf files from the manufacturer of each sensor with details on the sensor specifications. Each sensor subfolder (BarotrollAtm, MantaRiver, and MinidotManualChamber) contains a sensor data subfolder for timeseries data and a subfolder for plots and summary statistics. The BarotrollAtm Data subfolder contains In Situ Rugged BaroTROLL pressure and temperature data. The MantaRiver Data subfolder contains Eureka Manta+ 35B multisonde temperature, specific conductance, and pH data. The MinidotManualChamber Data subfolder contains PME MiniDOT Logger dissolved oxygen (mg/L and percent saturation) and temperature data. The folder SFA_SpatialStudy_2021_EnvironmentalContextPhotos contains environmental context photographs and videos. The folders SFA_SpatialStudy_2021_SedimentQuadratPhotos_Part1 and SFA_SpatialStudy_2021_SedimentQuadratPhotos_Part2 contain sediment quadrat photographs. All files are .csv, .pdf, .R, .jpg, .jpeg, .mp4, or .mov. This data package was originally published September 2022. It was updated January 2023 (modified files) and June 2024 (new and modified files). See the change history in data package readme for more details.We acknowledge the Yakama Nation as owners and caretakers of the lands where we collected these data. We thank the Confederated Tribes and Bands of the Yakama Nation Tribal Council and Yakama Nation Fisheries for working with us to facilitate sample collection and optimization of data usage according to their values and worldview.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Temporal Study 2022-2024: Sensor-Based Time Series of Surface Water Temperature, Specific Conductance, Total Dissolved Solids, Turbidity, Chlorophyll A, and Dissolved Oxygen from across Multiple Watersheds in the Yakima River Basin in Washington, USA

This dataset supports a broader study examining the drivers of temporal variability in sediment respiration rates in the Yakima River Basin. The dataset provides periodic (bi-weekly or monthly) in situ hydrological and water chemistry sensor data, handheld sensor water chemistry data, general environmental context photos, and field metadata collected at six sites across the Yakima River Basin in Washington, USA. Sample and sensor data from previous years (2021-2022) can be found at https://data.ess-dive.lbl.gov/datasets/doi:10.15485/1898912 and https://data.ess-dive.lbl.gov/datasets/doi:10.15485/1892054, respectively. Related sample data from 2022-2024 are available at https://data.ess-dive.lbl.gov/datasets/doi:10.15485/2562910. For details on how to navigate data packages generated by this project, see https://data.ess-dive.lbl.gov/portals/PNNLRiverCorridorSFA/About. In addition to a readme, this data package also includes a file-level metadata (FLMD) file that describes each file and a data dictionary (DD) that describes all column/row headers and variable definitions This dataset contains a folder of environmental context photographs and videos and (1) file-level metadata; (2) data dictionary; (3) readme; (4) field metadata; (5) field protocols; (6) international generic sample number (IGSN) mapping file; (7) handheld sensor data; and (8) two sensor subfolders. Each sensor subfolder (BarotrollAtm and MantaRiverData) contains a subfolder containing sensor time series data and plots. The BarotrollAtm Data subfolder contains In Situ Rugged BaroTROLL sensor pressure and air temperature data. The MantaRiverData subfolder contains Eureka Manta+ 35B multisonde temperature, specific conductance, and chlorophyll A. All files are .csv, .pdf, .jpg, .jpeg, .mp4, .png, or .mov.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2013

Novel Battery Management System with Distributed Wireless and Fiber Optic Sensors for Early Detection and Suppression of Thermal Runaway in Large Battery Packs, FY13 Q4 Report, ARPA-E Program: Advanced Management Protection of Energy Storage Devices (AMPE

Technology has been developed that enables monitoring of individual cells in highcapacity lithium-ion battery packs, with a distributed array of wireless Bluetooth 4.0 tags and sensors, and without proliferation of extensive wiring harnesses. Given the safety challenges facing lithium-ion batteries in electric vehicle, civilian aviation and defense applications, these wireless sensors may be particularly important to these emerging markets. These wireless sensors will enhance the performance, reliability and safety of such energy storage systems. Specific accomplishments to date include, but are not limited to: (1) the development of wireless tags using Bluetooth 4.0 standard to monitor a large array of sensors in battery pack; (2) sensor suites enabling the simultaneous monitoring of cell voltage, cell current, cell temperature, and package strain, indicative of swelling and increased internal pressure, (3) small receivers compatible with USB ports on portable computers; (4) software drivers and logging software; (5) a 7S2P battery simulator, enabling the safe development of wireless BMS hardware in the laboratory; (6) demonstrated data transmission out of metal enclosures, including battery box, with small variable aperture opening; (7) test data demonstrating the accurate and reliable operation of sensors, with transmission of terminal voltage, cell temperature and package strain at distances up to 110 feet; (8) quantification of the data transmission error as a function of distance, in both indoor and outdoor operation; (9) electromagnetic interference testing during operation with live, high-capacity battery management system at Yardney Technical Products; (10) demonstrated operation with live high-capacity lithium-ion battery pack during charge-discharge cycling; (11) development of special polymer-gel lithium-ion batteries with embedded temperature sensors, capable of measuring the core temperature of individual of the cells during charge-discharge cycling at various temperatures, thereby enabling earlier warning of thermal runaway than possible with external sensors. Ultimately, the team plans to extend this work to include: (12) flexible wireless controllers, also using Bluetooth 4.0 standard, essential for balancing large-scale battery packs. LLNL received $925K for this project, and has $191K remaining after accomplishing these objectives.

25 ENERGY STORAGE↗
DOE OSTI2014

Technical Assistance for Remote Sensor Placement Related Projects for Structural Health Monitoring

The world’s infrastructure is aging and many aspects are cost prohibitive to replace or even repair unless critically necessary. The standard way of determining if these repairs are critical or not is usually dependent on trained visual individual inspection. This process is very time consuming and costly considering the large areas and various structures that need to be monitored. A cost effective solution to this problem is to be able to monitor structures, such as roads, buildings, and bridges with remote sensors. Developing this solution provides some unique challenges such as sensor placement, types of sensors, energy needs for placed sensors, and data retrieval. As for the aspect of sensor placement, one method is to fly semi-autonomous Unmanned Arial Vehicles (UAVs) loaded with a sensor deployment mechanism to the structures so as to place the sensor and perhaps retrieve data from previously placed sensors as well. Many tests need to be run to determine the best UAV structure and deployment system to fulfill this task. It is hoped that through a multidisciplinary engineering scope the most effective process of monitoring the aging infrastructure can be developed.

42 ENGINEERING↗
DOE OSTI2015

Airborne Sensor Thermal Management Solution

The customer wants to outfit aircraft (de Havilland Twin Otter) with optical sensors. In previous product generations the sensor line-of-sight direction was fixed – the sensor’s direction relied on the orientation of the aircraft. The next generation sensor will be packaged in a rotatable turret so that the line-of-sight is reasonably independent of the aircraft’s orientation. This turret will be mounted on a boom protruding from the side of the aircraft. The customer wants to outfit aircraft (de Havilland Twin Otter) with optical sensors. In previous product generations the sensor line-of-sight direction was fixed – the sensor’s direction relied on the orientation of the aircraft. The next generation sensor will be packaged in a rotatable turret so that the line-of-sight is reasonably independent of the aircraft’s orientation. This turret will be mounted on a boom protruding from the side of the aircraft.

42 ENGINEERING↗
DOE OSTI2016

Dynamic Multi-Sensor Multi-Mission Optimal Planning Tool

Remote sensing systems have firmly established a role in providing immense value to commercial industry, scientific exploration, and national security. Continued maturation of sensing technology has reduced the cost of deploying highly-capable sensors while at the same time increased reliance on the information these sensors can provide. The demand for time on these sensors is unlikely to diminish. Coordination of next-generation sensor systems, larger constellations of satellites, unmanned aerial vehicles, ground telescopes, etc. is prohibitively complex for existing heuristics-based scheduling techniques. The project was a two-year collaboration spanning multiple Sandia centers and included a partnership with Texas A&M University. We have developed algorithms and software for collection scheduling, remote sensor field-of-view pointing models, and bandwidth-constrained prioritization of sensor data. Our approach followed best practices from the operations research and computational geometry communities. These models provide several advantages over state of the art techniques. In particular, our approach is more flexible compared to heuristics that tightly couple models and solution techniques. First, our mixed-integer linear models afford a rigorous analysis so that sensor planners can quantitatively describe a schedule relative to the best possible. Optimal or near-optimal schedules can be produced with commercial solvers in operational run-times. These models can be modified and extended to incorporate different scheduling and resource constraints and objective function definitions. Further, we have extended these models to proactively schedule sensors under weather and ad hoc collection uncertainty. This approach stands in contrast to existing deterministic schedulers which assume a single future weather or ad hoc collection scenario. The field-of-view pointing algorithm produces a mosaic with the fewest number of images required to fully cover a region of interest. The bandwidth-constrained algorithms find the highest priority information that can be transmitted. All of these are based on mixed-integer linear programs so that, in the future, collection scheduling, field-of-view, and bandwidth prioritization can be combined into a single problem. Experiments conducted using the developed models, commercial solvers, and benchmark datasets have demonstrated that proactively scheduling against uncertainty regularly and significantly outperforms deterministic schedulers.

47 OTHER INSTRUMENTATION↗
DOE OSTI2020

Literature Review for Sensor Impact Evaluation and Verification Use Cases - Building Controls and Fault Detection and Diagnosis (FDD)

This report summarizes a comprehensive literature review for the selected sensor suites used in building controls and fault detection and diagnostics (FDD), which is a Q2 deliverable of the Sensor Impact Evaluation and Verification project. The project’s overarching goal is to develop a framework for investigating the impact of sensor deployment and configuration for building energy optimization, fault detection and diagnosis (FDD), occupants’ thermal comfort, and potential grid efficiency. While the first phase of the literature review performed in Q1 reviewed the current methods of various sensor selection and placements and their impact, this report focuses on high impactful potential use cases for the selected sensor suites in building control and FDD. The use cases identified in this literature review will be further investigated and be included in the final sensor impact evaluation framework. For the review, the multi-laboratory team reviewed 241 research papers, technical reports, and books to identify existing technologies, the potential impact on energy savings and thermal comfort, and future research opportunities for the selected use cases in building controls and FDD. Along with the literature review, the team conducted a series of interviews with experts in sensors and controls area to identify the state-of-art sensor technologies, and the most impactful use cases in controls and FDD areas. The interview results will also be incorporated with the findings from the literature review in the next quarter, and the final use cases to be evaluated will be selected.

47 OTHER INSTRUMENTATION↗
DOE OSTI2020

Demonstrate embedding of sensors in a relevant microreactor component

This report describes the first successful embedding of sensors in stainless steel pipe specimens and a miniature hex block to support structural health monitoring of microreactor components during electrically heated testing in non-nuclear testbed facilities. Sensors were embedded with an ultrasonic additive manufacturing process that uses a combination of downward pressure and an ultrasonic scrubbing motion to bond stainless steel foils to underlying materials. After placing sensors within cavities that have been machined to the size of the sensors, the ultrasonic bonding process fills the gaps around the sensors and embeds them within the part. Both Type K thermocouples and spatially distributed fiber-optic strain sensors were successfully embedded within two pipe specimens and a miniature hex block. After the fiber-optic sensors were embedded, they were interrogated and found to have minimal signal attenuation within the embedded region—a significant improvement compared to previous trials. This is likely because of the low-bend-loss fiber that was used, which greatly reduces microbending losses that occur after the embedding process. In addition to showing minimal signal attention, the fibers also showed adequate compressive strain, which is a strong indication that the sensors are physically embedded in the parts as opposed to simply being loosely contained inside the machined cavities. The embedded fibers were able to capture the strain induced in one of the pipe specimens while the pipe was actively heated with a moving heat source.

42 ENGINEERING↗
DOE OSTI2021

Characterization of Embedded Sensors in Stainless Steel Test Articles and Design/Planning for MAGNET Testing

The nuclear industry is pursuing microreactors that can be factory assembled and deployed to remote regions for reliable power generation. One class of microreactors uses a monolithic metal core block coupled to heat pipes for heat rejection, which results in significant thermal stresses in the monolithic structures. This work describes the initial characterization and test plan for evaluating stainless steel test articles fabricated with embedded sensors for measuring heat pipe performance limits, as well as spatially distributed temperatures and strains during electrically heated thermal testing. The electrically heated testing will be performed in the non-nuclear Microreactor Agile Non-Nuclear Testbed and Single Primary Heat Extraction and Removal Emulator facilities located at Idaho National Laboratory. The goals of these tests are to (1) accurately monitor temperature and strain distributions that result from differential thermal expansion in the test articles and (2) quantify heat rejection limits of heat pipes as a function of operating temperature and working fluid during steady-state and transient operations. More generally, the ability to monitor component and system health during microreactor operation is attractive for providing a high sensor density to inform a limited number of microreactor operators to ultimately reduce operation and maintenance costs and move toward semi-autonomous operation. This report discusses the characterization of embedded thermocouples and fiber optic sensors in relevant test articles, including cylindrical pipes and hexagonal monolithic test articles for heat pipe-based reactors. The sensors were embedded by placing them in machined channels and then building up additional material by using ultrasonic additive manufacturing (UAM). UAM is a solid-state welding process that uses downward pressure and a lateral scrubbing motion to bond thin metal foils to a base material layer by layer. The ultrasonic welding process relies on the plastic deformation of the metal—as opposed to typical melting and solidification—to break oxide scales and bond the metal layers. The characterization of these embedded sensors included evaluating fiber optic signal attenuation, observing residual strain in the fibers, investigating microstructural and mechanical aspects, and demonstrating the sensors under various thermal loads and acoustic vibrations. Post-embedding characterization showed a fine grain structure (<1 μm) near the interfaces of the bonded foils as a result of severe deformation from the welding process. A large increase in hardness was observed at the foil interfaces and the fiber/matrix interface compared with the bulk matrix. Even when compared with the SS304 interfaces, the higher hardness observed around the embedded fiber suggests a higher degree of deformation due to the soft metal coating around the silica fiber core. The distributed fiber-optic temperature sensors and embedded thermocouples reliably measured temperature distributions during steady-state and transient thermal testing. The embedded fiber-optic sensors reliably measured strain during both transient and steady-state testing and properly identified resonant frequencies during acoustic testing.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗