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At least 505 records · Page 28

The case for digital twins in metal additive manufacturing

The digital twin (DT) is a relatively new concept that is finding increased acceptance in industry. A DT is generally considered as comprising a physical entity, its virtual replica, and two-way digital data communications in-between. Its primary purpose is to leverage the process intelligence captured within digital models—or usually their faster-solving surrogates—towards generating increased value from the physical entities. The surrogate models are created using machine learning based on data obtained from the field, experiments and digital models, which may be physics-based or statistics-based. Anomaly detection and correction, and diagnostic closed-loop process control are examples of how a process DT can be deployed. In the manufacturing industry, its use can achieve improvements in product quality and process productivity. Metal additive manufacturing (AM) stands to gain tremendously from the use of DTs. This is because the AM process is inherently chaotic, resulting in poor repeatability. However, a DT acting in a supervisory role can inject certainty into the process by actively keeping it within bounds through real-time control commands. Closed-loop feedforward control is achieved by observing the process through sensors that monitor critical parameters and, if there are any deviations from their respective optimal ranges, suitable corrective actions are triggered. The type of corrective action (e.g. a change in laser power or a modification to the scanning speed) and its magnitude are determined by interrogating the surrogate models. Because of their artificial intelligence (AI)-endowed predictive capabilities, which allow them to foresee a future state of the physical twin (e.g. the AM process), DTs proactively take context-sensitive preventative steps, whereas traditional closed-loop feedback control is usually reactive. Apart from assisting a build process in real-time, a DT can help with planning the build of a part by pinpointing the optimum processing window relevant to the desired outcome. Again, the surrogate models are consulted to obtain the required information. In this article, we explain how the application of DTs to the metal AM process can significantly widen its application space by making the process more repeatable (through quality assurance) and cheaper (by getting builds right the first time).

36 MATERIALS SCIENCE↗

Bayes_Opt-SWMM: A Gaussian process-based Bayesian optimization tool for real-time flood modeling with SWMM

Real-time flood model plays a pivotal role in averting urban flood damage, particularly when there is minimal lead time for preparatory measures. However, urban flood modeling in real-time often contends with inherent uncertainties arising from input data uncertainty and parameter ambiguities. Here this study introduces a real-time calibration (RTC) tool called Bayes_Opt-SWMM, specifically tailored for real-time urban flood modeling and uncertainty optimization. This tool leverages the Gaussian process-based Bayesian optimization algorithm and interfaces seamlessly with the Stormwater Management Model (SWMM). It integrates real-time model forcing data and flood monitoring collected through sensors and gauges which are strategically placed within critical locations of urban drainage systems. Our approach hinges on the Surrogate Model based Uncertainty Optimization (SMUO) concept, providing an avenue for enhancing real-time flood modeling. Bayes_Opt-SWMM runs the optimization process using a surrogate model called Gaussian Process emulator with two inference methods: (1) the Gaussian Process (GP) model and (2) Markov Chain Monte Carlo (MCMC) algorithm in GP model (GP_MCMC). Furthermore, three acquisition functions, namely Expected Improvement (EI), Maximum Probability of Improvement (MPI), and Lower Confidence Bound (LCB), facilitate optimal parameter fitting within the surrogate models. The efficiency of GP-based surrogate models in learning SWMM model parameters, leads to an improved uncertainty quantification and accelerated real-time flood modeling in urban areas. Overall, Bayes_Opt-SWMM emerges as a cost-effective and valuable tool for real-time flood modeling and monitoring, with significant potential for managing intelligent storm water systems in urban environments.

54 ENVIRONMENTAL SCIENCES↗

Use of a Magnetic Azimuth-Indicator System Developed for Balloon Payloads of the Planetary Entry Parachute Program

An azimuth-sensing system was used for continuous ground monitoring of the azimuth orientation of the balloon-borne Planetary Entry Parachute Program (PEPP) spacecraft. The system utilized two magnetic field sensors located in the spacecraft so as to produce a unique set of voltage outputs for any azimuth. Electronics onboard the spacecraft encoded the magnetometer outputs and fed the encoded signal to a C-band modulator which imposed the intelligence onto the radar tracking beacon pulses. A conveniently located ground radar received the modulated pulses and the magnetometer outputs were reproduced after demodulation. For fast, direct readout, an X-Y plotter was calibrated to cross plot the reproduced signal of the two magnetometers on a combination rectangular-polar graph indicating the correct true azimuth in real time. The method was used successfully on three of the PEPP balloon-borne spacecraft to determine when the spacecraft was pointed in the most advantageous direction for release from the balloon, at 130,000 ft altitude. The use of such a system of azimuth monitoring is suitable to balloon payloads which are virtually stable with respect to the horizontal but may be rotating about the vertical axis. Angular accuracies within plus or minus 10 deg. could generally be expected.

Darnell, Wayne L.↗

Generalist multimodal AI: A review of architectures, challenges and opportunities

Multimodal models are expected to be a critical component to future advances in artificial intelligence. Here, this field is starting to grow rapidly with a surge of new design elements motivated by the success of foundation models in natural language processing (NLP) and vision. It is widely hoped that further extending the foundation models to multiple modalities (e.g., text, image, video, sensor, time series, graph, etc.) will ultimately lead to generalist multimodal models, i.e. one model across different data modalities and tasks. However, there is little research that systematically analyzes recent multimodal models (particularly the ones that work beyond text and vision) with respect to the underling architecture proposed. Therefore, this work provides a fresh perspective on generalist multimodal models (GMMs) via a novel architecture and training configuration specific taxonomy. This includes factors such as Unifiability, Modularity, and Adaptability that are pertinent and essential to the wide adoption and application of GMMs. The review further highlights key challenges and prospects for the field and guide the researchers into the new advancements.

Artificial intelligence (AI)↗

Smart Pixel Sensors for the HL-LHC

Large-scale particle physics experiments produce tens of terabytes of data every second. Innovative methods to manage the data rate at the HL-LHC, which expects to operate at 10x the luminosity of what the LHC was initially designed for, are needed. AI-on the chip provides a way to intelligently filter out low momentum clusters in the pixel detector. This will open up an opportunity to use the pixel detector for the first time in the CMS Level-1 trigger, and lead to increased sensitivity to new physics measurements and searches. We have taped out our first chip, which incorporates a $p_T$ filtering algorithm on an ASIC chip. Our initial $p_T$ filtering algorithm considers clusters that are tracked by CMS. We will report on ongoing studies seeking to enhance the performance of our filter by utilizing unsupervised learning on untracked clusters, thus increasing background rejection.

43 PARTICLE ACCELERATORS↗

Telerobotics for the efficient utilization of space

Telerobotics is a new technology that is being developed to perform remote manipulation in space. It seeks to accommodate the needs arising from a rapidly increasing investment in space assets and from the large costs deriving from human operations in space, especially EVA. Telerobotics applies advanced automation and artificial intelligence technology and combines the immediacy of execution of teleoperation (the replication at a distance of the physical motions of the operator) with the efficiency and precision of supervised robotic autonomy (the accomplishment of assignments through machine task decomposition and interpretation of sensor information). One of the key goals of this approach is the achievement of a seamless transition between teleoperation and supervised autonomy. The basis of this technology and of the NASA telerobotics research and development activities are described. They consist of five elements: core research, laboratory integration testbed, mission analysis, application demonstrations and flight experiments. Current advances, both in research and system integration are reported including the first integration of the laboratory testbed and quantitative comparisons obtained in a buoyant facility. Planned future goals are outlined.

Varsi, Giulio↗

Intelligent fault isolation and diagnosis for communication satellite systems

Discussed here is a prototype diagnosis expert system to provide the Advanced Communication Technology Satellite (ACTS) System with autonomous diagnosis capability. The system, the Fault Isolation and Diagnosis EXpert (FIDEX) system, is a frame-based system that uses hierarchical structures to represent such items as the satellite's subsystems, components, sensors, and fault states. This overall frame architecture integrates the hierarchical structures into a lattice that provides a flexible representation scheme and facilitates system maintenance. FIDEX uses an inexact reasoning technique based on the incrementally acquired evidence approach developed by Shortliffe. The system is designed with a primitive learning ability through which it maintains a record of past diagnosis studies.

Tallo, Donald P.↗

Automated rendezvous and docking with video imagery

For rendezvous and docking, assessing and tracking relative orientation is necessary within a minimum approach distance. Special target light patterns have previously been considered for use with video sensors for ease of determining relative orientation. A generalization of those approaches is addressed. At certain ranges, the entire structure of the target vehicle constitutes an acceptable target; at closer ranges, substructures will suffice. Acting on the same principle as the human intelligence, these structures can be compared with a memory model to assess the relative orientation and range. Models for comparison are constructed from a CAD facet model and current imagery. This approach requires fast image handling, projection, and comparison techniques which rely on rapidly developing parallel processing technology. Relative orientation and range assessment consists of successful comparison of the perceived target aspect with a known aspect. Generating a known projection from a model within required times, say subsecond times, is only now approaching feasibility. With this capability, rates of comparison used by the human brain can be approached and arbitrary known structures can be compared in reasonable times. Future space programs will have access to powerful computation devices which far exceed even this capability. For example, the possibility will exist to assess unknown structures and then control rendezvous and docking, all at very fast rates. The first step which has the current utility, namely applying this to known structures, is taken.

Rodgers, Mike↗

Remote Sensing Product Verification and Validation at the NASA Stennis Space Center

Remote sensing data product verification and validation (V&V) is critical to successful science research and applications development. People who use remote sensing products to make policy, economic, or scientific decisions require confidence in and an understanding of the products' characteristics to make informed decisions about the products' use. NASA data products of coarse to moderate spatial resolution are validated by NASA science teams. NASA's Stennis Space Center (SSC) serves as the science validation team lead for validating commercial data products of moderate to high spatial resolution. At SSC, the Applications Research Toolbox simulates sensors and targets, and the Instrument Validation Laboratory validates critical sensors. The SSC V&V Site consists of radiometric tarps, a network of ground control points, a water surface temperature sensor, an atmospheric measurement system, painted concrete radial target and edge targets, and other instrumentation. NASA's Applied Sciences Directorate participates in the Joint Agency Commercial Imagery Evaluation (JACIE) team formed by NASA, the U.S. Geological Survey, and the National Geospatial-Intelligence Agency to characterize commercial systems and imagery.

Stanley, Thomas M.↗

MAC/GMC Code Enhanced for Coupled Electromagnetothermoelastic Analysis of Smart Composites

Intelligent materials are those that exhibit coupling between their electromagnetic response and their thermomechanical response. This coupling allows smart materials to react mechanically (e.g., an induced displacement) to applied electrical or magnetic fields (for instance). These materials find many important applications in sensors, actuators, and transducers. Recently interest has arisen in the development of smart composites that are formed via the combination of two or more phases, one or more of which is a smart material. To design with and utilize smart composites, designers need theories that predict the coupled smart behavior of these materials from the electromagnetothermoelastic properties of the individual phases. The micromechanics model known as the generalized method of cells (GMC) has recently been extended to provide this important capability. This coupled electromagnetothermoelastic theory has recently been incorporated within NASA Glenn Research Center's Micromechanics Analysis Code with Generalized Method of Cells (MAC/GMC). This software package is user friendly and has many additional features that render it useful as a design and analysis tool for composite materials in general, and with its new capabilities, for smart composites as well.

Bednarcyk, Brett A.↗

An Artificial-Intelligence and Machine-Learning-Based Methodology to Conduct Seemingly Strain-Controlled Fatigue Test in a Pressurized-Water-Reactor-Test-Loop-Autoclave, While Not Controlling the Strain

In general, low cycle fatigue analysis of pressurized water reactor (PWR) components, requires strain-controlled fatigue test data such as using strain versus life (ε–N) curves. Conducting strain-controlled fatigue tests under in-air conditions is not an issue. However, controlling strain in a PWR-test-loop-autoclave is a challenge, since an extensometer cannot be placed in a narrow autoclave (typically used in a high-temperature-pressure PWR-test-loop). This is due to lack of space inside an autoclave that houses the test specimen. In addition, installing a contact-type extensometer in the path of a high-pressure flow can be a challenge. These difficulties of using an extensometer inside an autoclave led us to use an outside-autoclave displacement sensor which measures the displacement of pull-rod-specimen assembly. However, in our study (based on in-air fatigue test data), we found that a pull-rod-controlled based fatigue test can lead to substantial cyclic hardening/softening resulting in substantially different cyclic strain amplitudes and their rates compared to the desired cyclic strain amplitudes and its rates. In this paper, we propose an Artificial-Intelligence and Machine-Learning based technique such as using k-means clustering technique to improve the pull-rod-control based fatigue test method, such that the gage-area strain amplitude and rates can reasonably be achieved. In support of this, we present the fatigue test results for both 316 SS base and 81/182 dissimilar-metal-weld specimens.

42 ENGINEERING↗

Physics-Based Methods of Failure Analysis and Diagnostics in Human Space Flight

The Integrated Health Management (IHM) for the future aerospace systems requires to interface models of multiple subsystems in an efficient and accurate information environment at the earlier stages of system design. The complexity of modern aeronautic and aircraft systems (including e.g. the power distribution, flight control, solid and liquid motors) dictates employment of hybrid models and high-level reasoners for analysing mixed continuous and discrete information flow involving multiple modes of operation in uncertain environments, unknown state variables, heterogeneous software and hardware components. To provide the information link between key design/performance parameters and high-level reasoners we rely on development of multi-physics performance models, distributed sensors networks, and fault diagnostic and prognostic (FD&P) technologies in close collaboration with system designers. The main challenges of our research are related to the in-flight assessment of the structural stability, engine performance, and trajectory control. The main goal is to develop an intelligent IHM that not only enhances components and system reliability, but also provides a post-flight feedback helping to optimize design of the next generation of aerospace systems. Our efforts are concentrated on several directions of the research. One of the key components of our strategy is an innovative approach to the diagnostics/prognostics based on the real time dynamical inference (DI) technologies extended to encompass hybrid systems with hidden state trajectories. The major investments are into the multiphysics performance modelling that provides an access of the FD&P technologies to the main performance parameters of e.g. solid and liquid rocket motors and composite materials of the nozzle and case. Some of the recent results of our research are discussed in this chapter. We begin by introducing the problem of dynamical inference of stochastic nonlinear models and reviewing earlier results. Next, we present our analytical approach to the solution of this problem based on the path integral formulation. The resulting algorithm does not require an extensive global search for the model parameters, provides optimal compensation for the effects of dynamical noise, and is robust for a broad range of dynamical models. In the following Section the strengths of the algorithm are illustrated illustrated by inferring the parameters of the stochastic Lorenz system and comparing the results with those of earlier research. Next, we discuss a number of recent results in application to the development of the IHM for aerospace system. Firstly, we apply dynamical inference approach to a solution of classical three tank problems with mixed unknown continuous and binary parameters. The problem is considered in the context of ground support system for filling fuel tanks of liquid rocket motors. It is shown that the DI algorithm is well suited for successful solution of a hybrid version of this benchmark problem even in the presence of additional periodic and stochastic perturbation of unknown strength. Secondly, we illustrate our approach by its application to an analysis of the nozzle fault in a solid rocket motor (SRM). The internal ballistics of the SRM is modelled as a set of one-dimensional partial differential equations coupled to the dynamics of the propellant regression. In this example we are specifically focussed on the inference of discrete and continuous parameters of the nozzle blocking fault and on the possibility of an application of the DI algorithm to reducing the probability of "misses" of an on-board FD&P for SRM. In the next section re-contact problem caused by first stage/upper stage separation failure is discussed. The reaction forces imposed on the nozzle of the upper stage during the re-contact and their connection to the nozzle damage and to the thrust vector control (TVC) signal are obtained. It is shown that transient impact induced torquean be modelled as a response of an effective damped oscillator. A possible application of the DI algorithm to the inference of damage parameters and predicting fault dynamics ahead of time using the actuator signal is discussed. Finally, we formulate Bayesian inferential framework for development of the IHM system for in-flight structural health monitoring (SHM) of composite materials. We consider the signal generated by piezoelectric actuator mounted on composite structure generating elastic waves in it. The signal received by the sensor is than compared with the baseline signal. The possibility of damage inference is discussed in the context of development of the SHM.

Smelyanskiy, Vadim N.↗

Report on Progress of correlation of in-situ and ex-situ data and the use of artificial intelligence to predict defects

The Transformational Challenge Reactor (TCR) program is leveraging additive manufacturing (AM) technologies to fabricate nuclear components which will be assembled into a fully functional microreactor core. Compared with traditional manufacturing technologies, AM technologies allow (1) real-time observation of the manufacturing process at a much higher resolution using in-situ monitoring technologies to capture the sensor signatures that scientifically describe each event occurring over time and space and (2) validation of the manufacturing process quality using domain-informed data analytics techniques as a potential qualification and certification methodology for the final component. This report provides an update on the program work on in-situ and ex-situ data correlation and associated data analytics results. Examples are provided to illustrate progress with respect to laser powder bed fusion (L-PBF), binder jetting, computed tomography (CT) reconstruction, and mechanical testing. Elements of the Digital Thread and data management infrastructure are discussed in the main document, and an extensive supplemental appendix is provided detailing the Digital Platform, as well as its implementation and subcomponents. In conclusion, the path forward for the next fiscal year is also discussed.

42 ENGINEERING↗

Vehicle following controller design for autonomous intelligent vehicles

A new vehicle following controller is proposed for autonomous intelligent vehicles. The proposed vehicle following controller not only provides smooth transient maneuvers for unavoidable nonzero initial conditions but also guarantees the asymptotic platoon stability without the availability of feedforward information. Furthermore, the achieved asymptotic platoon stability is shown to be robust to sensor delays and an upper bound for the allowable sensor delays is also provided in this paper.

Chien, C. C.↗

Hydrogen Detection Strategies to Support H2@SCALE - The NREL Sensor Laboratory

Hydrogen represents a major pathway to decarbonize and stabilize the national and international energy industry and select manufacturing markets. To facilitate the development of hydrogen markets, the US Department of Energy initiated H2@Scale to bring together stakeholders to advance affordable hydrogen production, transport, storage, and utilization to increase revenue opportunities in multiple energy sectors. One major impediment to hydrogen implementation is cost. To expedite the use of hydrogen in energy and other markets, the United States announced in 2021 the Hydrogen Shot, which seeks to reduce the cost of clean hydrogen by 80% to $1 per 1 kilogram in 1 decade ("1 1 1"). As the cost of hydrogen drops, new applications will emerge that will require unique configurations of existing equipment and infrastructure, and eventually lead to advances in the generation and utilization of hydrogen. As the hydrogen economy expands, sensors and detection methods will need to adapt to changing infrastructure demands to address the primary targets of health & safety, emissions monitoring, and process control. The NREL Sensor Laboratory is playing a pivotal role in advancing the use of hydrogen sensors and detection methodologies in each of these categories to support DOE's mission for safe and efficient utilization in emerging markets. Health & safety monitors are required to ensure that operators and facilities can react to unintended hydrogen releases, either as GH2, LH2, or as a constituent of blends (e.g., natural gas or ammonia). Current detection methodologies focus on safety applications to detect near its lower flammable limit (4 vol %), and typically include point sensors in applications such as fixed or mobile detectors (e.g., personal gas monitors). Methodologies amenable for area detection include acoustic, emerging optical imaging methods, and flame detectors. Comparable detection strategies can be utilized for emissions monitoring and quantization, however few methods can simultaneously cover both low (emissions) and high (health & safety) levels. Deployment of emission level detectors will be required to 1) reduce product loss through small but potentially significant leaks from an environmental or cost perspective, 2) reduce downtime of high demand systems by early identification of eminent system failures (leaks through pump or compressor seals indicative of impending failure), and 3) address potential emission monitoring requirements that may be set by regulating bodies. The first two points should be adopted by industry to reduce the cost-of-goods-sold. The third main category for hydrogen detection relates to process control and may be advantageous for many existing applications. Two main applications are emerging. For example, the purity requirements for hydrogen that is dispensed from refueling systems for hydrogen fuel cell electric vehicles (FCEV) is rigorously regulated by the Standard SAE J2719, which prescribes maximum allowable levels of multiple impurities in the hydrogen fuel and must be verified by a regulatory body. Hydrogen contaminant detectors (HCD) integrated to the fueling station can assure this compliance. HCDs must be able operate in 100% H2 backgrounds and be able to distinguish between multiple contaminants at low ppm to low ppb levels. Secondly, as a strategy to decarbonize the natural gas grid, there are proposals to blend hydrogen with natural gas. This blending will affect transport applications (pipeline infrastructure), stationary combustion systems (turbines), and consumer and commercial appliances. In the short-term, hydrogen levels up to 20% are proposed. Variations in the hydrogen level can have dramatic impact on the combustion process and on the potential response of safety sensors. These mixtures may be regulated so that the concentration at a delivery point must be monitored with high precision. However, routine maintenance may introduce background gases such as ambient air (with water) or maintenance gases (introduced with welding processes or adhesive outgassing.) Therefore, the detection methodology must be robust enough to recover or respond to various contaminants. Several reviews can be found in literature addressing sensing and detection technologies, including their limitations and applications. However, for most applications, limitations can be alleviated by combining various detection techniques either through system integration or implementation of machine learning methods (artificial intelligence). In this presentation, we will discuss several applications, highlight their current approach for hydrogen detection, and suggest detection strategies to supplement their limitations.

ENERGY STORAGE,HYDROGEN↗

Monitoring of Structural Integrity of Composite Structures by Embedded Optical Fiber Sensors

Real time monitoring of the mechanical integrity and stresses on key aerospace composite structures like aircraft wings, walls of pressure vessels and fuel tanks or any other structurally extended components and panels as in space telescopes is very important to NASA. Future military and commercial aircraft as well as NASA space systems such as Space Based Radar and International Space Station will incorporate a monitoring system to sense any degradation to the structure. In the extreme flight conditions of an aerospace vehicle it might be desirable to measure the strain every ten centimeters and thus fully map out the strain field of a composite component. A series of missions and vehicle health management requirements call for these measurements. At the moment thousands of people support a few vehicle launches per year. This number can be significantly reduced by implementing intelligent vehicles with integral nervous systems (smart structures). This would require maintenance to be performed only as needed. Military and commercial aircrafts have an equally compelling case. Maintenance yearly costs are currently reaching astronomical heights. Monitoring techniques are therefore required that allow for maintenance to be performed only when needed. This would allow improved safety by insuring that necessary tasks are performed while reducing costs by eliminating procedures that are costly and not needed. The advantages fiber optical sensors have over conventional electro-mechanical systems like strain gauges have been widely extolled in the research literature. These advantages include their small size, low weight, immunity to electrical resistance, corrosion resistance, compatibility with composite materials and process conditions, and multiplexing capabilities. One fiber optic device which is suitable for distributed sensing is the fiber Bragg grating (FBG). Researchers at NASA MSFC are currently developing techniques for using FBGs for monitoring the integrity of advanced structural materials expected to become the mainstay of the current and future generation space structures. Since carbon-epoxy composites are the materials of choice for the current space structures, the initial study is concentrated on this type of composite. The goals of this activity are to use embedded FBG sensors for measuring strain and temperature of composite structures, and to investigate the effects of various parameters such as composite fiber orientation with respect to the optical sensor, unidirectional fiber composite, fabrication process etc., on the optical performance of the sensor. This paper describes an experiment to demonstrate the use of an embedded FBG for measuring strain in a composite material. The performance of the fiber optic sensor is determined by direct comparison with results from more conventional instrumentation.

Albert J. Osei↗

Retina-inspired narrowband perovskite sensor array for panchromatic imaging

The retina is the essential part of the human visual system that receives light, converts it to neural signal, and transmits to brain for visual recognition. The red, green, and blue (R/G/B) cone retina cells are natural narrowband photodetectors (PDs) sensitive to R/G/B lights. Connecting with these cone cells, a multilayer neuro-network in the retina provides neuromorphic preprocessing before transmitting to brain. Inspired by this sophistication, we develop the narrowband (NB) imaging sensor combining R/G/B perovskite NB sensor array (mimicking the R/G/B photoreceptors) with a neuromorphic algorithm (mimicking the intermediate neural network) for high-fidelity panchromatic imaging. Compared to commercial sensors, we use perovskite “intrinsic” NB PD to exempt the complex optical filter array. In addition, we use an asymmetric device configuration to collect photocurrent without external bias, enabling a power-free photodetection feature. These results display a promising design for efficient and intelligent panchromatic imaging.

42 ENGINEERING↗