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At least 523 records · Page 29

Cold Spray Cobalt Magnetostrictive Electromagnetic Acoustic Transducers for High Temperature Structure Monitoring

The Department of Energy’s Advanced Sensors and Instrumentation program seeks to develop and qualify advanced sensors for the nuclear industry. Reliable high temperature and high radiation sensors for detection and characterization of structural flaws in pipes, vessels, and structurally critical components is a weakness for both conventional light water reactors with coolant T-hot approaching 350oC, and for advanced reactors with T-hot temperatures in excess of 500 to 800oC. Magnetostrictive Electromagnetic Acoustic Transducers using a cold spray cobalt coating have been proposed as a sensor design that can withstand these kinds of temperatures and radiation levels to serve as online sensors to detect flaws before cracks, pits, or erosion/corrosion flaws progress to through-wall failures. This report tests cold spray cobalt as part of a magnetostrictive EMAT for high temperature service. Cobalt is known to have strong magnetostrictive properties however the effect of cold spray application is not well studied. This program was surprised to discover that cold sprayed cobalt exhibited little or no magnetostrictive behavior until it was thermally annealed. Following annealing to 650oC however, cold spray cobalt did exhibit a magnetostrictive response. Work to date prior to this milestone report publication showed that magnetostrictive EMAT was successfully tested to 400oC with an alnico permanent magnet. The program plans to extend testing with an electromagnet to higher temperatures. This follow-on work will be reported under subsequent publications or as a revision to this report.

Glass, Samuel W.↗

Development of A Multi-Spectral Pyrometry Sensor for High-Speed Transient Surface-Temperature Measurements in Combustion-Relevant Harsh Environments

Accurate and high-speed transient surface-temperature measurements of combustion devices including internal combustion (IC) engines, gas turbines, etc., provide validation targets and boundary conditions for computational fluid dynamics models, and are broadly relevant to technology advancements such as performance improvement and emissions reduction. Development and demonstration of a multi-infrared-channel pyrometry-based optical instrument for high-speed surface-temperature measurement is described. The measurement principle is based on multi-spectral radiation thermometry (MRT) and uses surface thermal radiation at four discrete spectral regions and a corresponding emissivity model to obtain surface temperature via non-linear least squares (NLLS) optimization. Rules of thumb for specifying the spectral regions and considerations to avoid interference with common combustion products are developed; the impact of these along with linear and non-linear MRT analysis are assessed as a function of temperature and signal-to-noise ratio. A multi-start method to determine the MRT-solution global optimum is described and demonstrated. The resulting multi-channel transient pyrometry instrument is described along with practical considerations including optical-alignment drift, matching intra-channel transient response, and solution-confidence indicators. The instrument demonstrated excellent >97% accuracy and >99% 2-sigma precision over the 400–800 °C range, with ~20 µs (50 kHz, equivalent to 0.2 cad at 2000 RPM IC-engine operation) transient response in the bench validation.

47 OTHER INSTRUMENTATION↗

Hot, Cold, or Just Right? Using a Wide-View Infrared Biometric Sensor to Improve Occupant Comfort and Reduce Overcooling in Buildings via Closed-loop Control (CRADA Final Report)

This research adds to the understanding of building energy management by fundamentally challenging the long-standing paradigm of controlling an environmental parameter—air temperature—and assuming occupant comfort will follow. The project developed and demonstrated a novel approach that directly senses physiological indicators of human comfort to enable closedloop, human-centric control of heating, ventilation, and air conditioning (HVAC) systems. This work shifts the focus from open-loop environmental control to a closed-loop system that prioritizes the occupants' actual thermal state. The primary benefit to the public is the potential for a simultaneous improvement in the quality of indoor environments, where people spend most of their time, and a significant reduction in national energy consumption. Overcooling, or the overuse of cooling energy in a way that discomforts occupants, wastes approximately 0.5 Quads of primary energy annually in U.S. commercial buildings and creates unproductive indoor environments.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Embedding ceramic components in metal structures with hybrid directed energy deposition

The combined benefit of both additive and subtractive manufacturing within the same gantry system enables hybrid directed energy deposition to create complex geometries with smooth surface finish and superior dimensional accuracy. Moreover, with layer-by-layer access to the structure during both the addition and subtraction of material, the insertion of components is now possible, assuming the components can survive the high temperatures associated with the subsequent metal deposition. Ceramic inserts are of interest for a variety of reasons including (1) to create complex interwoven ductile/brittle composites for ballistics or high-temperature applications or (2) to integrate high-temperature strain or temperature sensors protected within ceramic substrate subsumed into a larger metal structure. Here, in this work, stainless steel substrates were machined to create an internal cavity for the insertion of a ceramic component. During the investigation of several different over-the-ceramic deposition strategies, components were inserted, and different process sequences were allowed to continue to envelop the inserted ceramic with varying success. Unmelted powder was used to serve both as a thermal buffer and to provide a flush surface upon which the laser cladding could continue. Subsequent depositions were attempted with both dry and wet powder (addition of machining coolant to wet). The wet powder has previously been demonstrated to not significantly impact the mechanical properties of a final structure and provided a thermal barrier to protect the ceramic piece from the extreme temperatures of the final metal deposition. The wetting of the powder provided stability and minimized displacement caused by the powder flow from the laser cladding head. Finally, the use of an oblique angle for laser cladding allowed for the redirection of some fraction of the introduced thermal energy away from the ceramic component and, consequently, improved the survival of the ceramic inserts. With this combination of techniques, ceramic inserts survived full embedding within a 3D-printed stainless steel structure.

36 MATERIALS SCIENCE↗

Leading in Los Angeles: Demonstrating scalable emerging energy efficient technologies for integrated façade, lighting, and plug loads INTER System FLEXLAB Test Report

This report is a part of the California Energy Commission (Energy Commission) EPIC study Leading in Los Angeles: Demonstrating scalable emerging energy efficient technologies for integrated façade, lighting, and HVAC. The set of technologies are called the Integrated Technologies for Energy-efficient Retrofits (INTER) and are comprised of automated shading products and LED lighting systems with networked luminaire-level sensors and controls. In addition, the project will include control modifications and assessments of HVAC savings. This document includes the test plan and test results for the FLEXLAB® testing of the shading and lighting INTER system and related energy use impact. The test plan describes the test objectives and features, test cases, schedule, and measurements. The test results cover system performance in the lab; including lighting and HVAC energy, visual comfort, and thermal comfort.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Acoustics Reveals Short–Term Air Temperature Fluctuations Near Mars' Surface

Acoustics is new on Mars: it allows the characterization of turbulence at smaller scales than previously possible within the lowest part of the Planetary Boundary Layer. Sound speed measurements, by the SuperCam instrument and its microphone onboard the NASA Perseverance rover, allow the retrieval of atmospheric temperatures at 0.77 m above the ground, at 3 Hz, with a ~10 ms response time that is 20–100 times shorter than for typical thermocouple sensors used on Mars. Here we report on the first measurements of the sound speed-derived temperature and its fluctuations near the surface. Data highlight large and rapid fluctuations up to ±7 K/s, whose amplitude over such a timescale has never been reported, nor predicted by atmospheric models. These fluctuations follow the daytime pattern of the turbulence and highlight occasional high amplitude events that are likely due to the conjunction of low thermal inertia and strong winds.

79 ASTRONOMY AND ASTROPHYSICS↗

A Bioinspired Artificial Injury Response System Based on a Robust Polymer Memristor to Mimic a Sense of Pain, Sign of Injury, and Healing

Abstract Flexible electronic skin with features that include sensing, processing, and responding to stimuli have transformed human–robot interactions. However, more advanced capabilities, such as human‐like self‐protection modalities with a sense of pain, sign of injury, and healing, are more challenging. Herein, a novel, flexible, and robust diffusive memristor based on a copolymer of chlorotrifluoroethylene and vinylidene fluoride (FK‐800) as an artificial nociceptor (pain sensor) is reported. Devices composed of Ag/FK‐800/Pt have outstanding switching endurance >10 6 cycles, orders of magnitude higher than any other two‐terminal polymer/organic memristors in literature (typically 10 2 –10 3 cycles). In situ conductive atomic force microscopy is employed to dynamically switch individual filaments, which demonstrates that conductive filaments correlate with polymer grain boundaries and FK‐800 has superior morphological stability under repeated switching cycles. It is hypothesized that the high thermal stability and high elasticity of FK‐800 contribute to the stability under local Joule heating associated with electrical switching. To mimic biological nociceptors, four signature nociceptive characteristics are demonstrated: threshold triggering, no adaptation, relaxation, and sensitization. Lastly, by integrating a triboelectric generator (artificial mechanoreceptor), memristor (artificial nociceptor), and light emitting diode (artificial bruise), the first bioinspired injury response system capable of sensing pain, showing signs of injury, and healing, is demonstrated.

36 MATERIALS SCIENCE↗

Quantum-enhanced sensing of displacements and electric fields with two-dimensional trapped-ion crystals

Fully controllable ultracold atomic systems are creating opportunities for quantum sensing, yet demonstrating a quantum advantage in useful applications by harnessing entanglement remains a challenging task. Here, we realize a many-body quantum-enhanced sensor to detect displacements and electric fields using a crystal of ~150 trapped ions. The center-of-mass vibrational mode of the crystal serves as a high- Q mechanical oscillator, and the collective electronic spin serves as the measurement device. By entangling the oscillator and collective spin and controlling the coherent dynamics via a many-body echo, a displacement is mapped into a spin rotation while avoiding quantum back-action and thermal noise. We achieve a sensitivity to displacements of 8.8 ± 0.4 decibels below the standard quantum limit and a sensitivity for measuring electric fields of 240 ± 10 nanovolts per meter in 1 second. Feasible improvements should enable the use of trapped ions in searches for dark matter.

Gilmore, Kevin A.↗

Pre-Symptomatic COVID Screening

Temperature checks for fever are extensively used for preliminary COVID screenings but are ineffective during the incubation stage of infection when a person is asymptotic. Researchers at the European Centre for Disease Prevention and Control concluded that approximately 75% of passengers infected with COVID-19 and traveling from affected Chinese cities would not be detected by early screening. Core body temperature is normally kept within a narrow range and has the smallest relative standard deviation of all vital signs. Heat in the body is prioritized around internal organs at the expense of the periphery by controlling blood flow. In fact, blood flow to the skin may vary by a factor of 100 depending on thermal conditions. This adaptation causes rapid temperature fluctuations in different skin regions from changes in cardiac output, metabolism, and likely cytokine diffusion during inflammation that would not be seen in average core body temperature. Current IR and thermal scanners used for temperature checks are not necessarily reflective of core body temperatures and require cautious interpretation as they frequently result in false positive and false negative diagnosis. Hand held thermometers measure average skin temperatures and can get readings that differ from core body temperature by as much as 7°. Rather than focusing on a core body temperature threshold assessment we believe that variability of temperature patterns using a novel wearable transdermal microneedle sensor will be more sensitive to infections in the incubation stage and propose to develop a wearable transdermal temperature sensor using established Sandia microneedle technology for pre-symptomatic COVID screening that can additionally be used to monitor disease progression at later stages.

47 OTHER INSTRUMENTATION↗

Pre Symptomatic COVID Screening

Temperature checks for fever are extensively used for preliminary COVID screenings but are ineffective during the incubation stage of infection when a person is asymptotic. Researchers at the European Centre for Disease Prevention and Control concluded that approximately 75% of passengers infected with COVID-19 and traveling from affected Chinese cities would not be detected by early screening. Core body temperature is normally kept within a narrow range and has the smallest relative standard deviation of all vital signs. Heat in the body is prioritized around internal organs at the expense of the periphery by controlling blood flow. In fact, blood flow to the skin may vary by a factor of 100 depending on thermal conditions. This adaptation causes rapid temperature fluctuations in different skin regions from changes in cardiac output, metabolism, and likely cytokine diffusion during inflammation that would not be seen in average core body temperature. Current IR and thermal scanners used for temperature checks are not necessarily reflective of core body temperatures and require cautious interpretation as they frequently result in false positive and false negative diagnosis. Hand held thermometers measure average skin temperatures and can get readings that differ from core body temperature by as much as 7°. Rather than focusing on a core body temperature threshold assessment we believe that variability of temperature patterns using a novel wearable transdermal microneedle sensor will be more sensitive to infections in the incubation stage and propose to develop a wearable transdermal temperature sensor using established Sandia microneedle technology for pre symptomatic COVID screening that can additionally be used to monitor disease progression at later stages.

59 BASIC BIOLOGICAL SCIENCES↗

Applying Infrared Thermography as a Method for Online Monitoring of Turbine Blade Coolant Flow

As gas turbine engine manufacturers strive to implement condition-based operation and maintenance, there is a need for blade monitoring strategies capable of early fault detection and root-cause determination. Given the importance of blade cooling flows to turbine blade health and longevity, there is a distinct lack of methodologies for coolant flowrate monitoring. The present study addresses this identified opportunity by applying an infrared thermography system on an engine-representative research turbine to generate data-driven models for prediction of blade coolant flowrate. Thermal images were used as inputs to a linear regression and regularization algorithm to relate blade surface temperature distribution with blade coolant flowrate. Additionally, this study investigates how coolant flowrate prediction accuracy is influenced by the number and breadth of diagnostic measurements. Here, the results of this study indicate that a source of high-fidelity training data can be used to predict blade coolant flowrate within about six percent error. Furthermore, identification of prioritized sensor placement supports application of this technique across multiple sensor technologies capable of measuring blade surface temperature in operating gas turbine engines, including spatially resolved and point-based measurement techniques.

42 ENGINEERING↗

Online Monitoring System for Concrete Structures Affected by Alkali-Silica Reaction

This report presents a comprehensive study of developing ultrasonic wave and acoustic emission (AE) techniques for long-term monitoring of alkali-silica reaction (ASR) development in concrete. Small, medium, and full-scale concrete specimens were cast, conditioned, and monitored for various periods, from at least one year to 2.4 years. The reactive concrete specimens contain coarse or fine reactive aggregates to study the effects of different types of reactive aggregates. Confinements were also designed to simulate the 2-dimensional confinement effects of reinforcement in the shield building of nuclear power plants. The concrete specimens were stored in a environmental chamber with high humidity and high temperature to accelerate the ASR development. The ultrasonic monitoring data shows high sensitivity to ASR development and could detect cracking initiation well before visible surface cracks occurred. However, the linear ultrasonic analysis based on wave velocity is strongly affected by temperature variation. Therefore, a nonlinear ultrasonic method was proposed to measure thermally induced nonlinear acoustic responses of concrete (thermal modulation of ultrasonic wave). The measured nonlinear acoustic parameter shows a high correlation with ASR expansion across specimens with different reactive aggregates and confinement conditions. The same conclusion was obtained from nonlinear resonance tests on small concrete prisms. Compared to the linear acoustic methods, the nonlinear tests show high sensitivities to ASR damage from internal microcracking initiation at the early stage to visible cracks at the late stage of ASR. The attributes of the thermal modulation of nonlinear ultrasonic method include high sensitivity, immunity to temperature effects, and strong correlation with ASR expansion, which demonstrate great potentials of the nonlinear ultrasonic method for diagnosis of ASR damage and prediction of concrete deterioration process. Acoustic emission is a passive sensing technique for damage assessment, and access to only one surface is needed even for thick and heavily reinforced elements such as the walls utilized for nuclear shield building. Additionally, relatively few sensors are required to monitor the progression of the damage process. Results indicate that the AE data can be related to the damage rating index, which is a petrography-based means of assessing damage due to ASR in reinforced concrete. Furthermore, AE is capable of detecting ASR damage long before surface cracking is visually noticeable. Boundary conditions play in important role in the progression of ASR damage and differences in boundary conditions are reflected in the AE data. Entropy based data assessment methods provide a means to assess the damage state, and convolutional neural network based data assessment provided a means to assess the damage state in real-time. Results indicate that artificial neural network models may be used as a means to predict volumetric expansion based on AE data.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Preliminary Plan to Inform Testing of a Heat Exchanger Test Article

This report presents a preliminary plan to guide the qualification testing of advanced heat exchanger (HX) components for nuclear-to-industrial heat transfer applications. The objective is to establish a defensible, physics-based methodology that integrates computational modeling, targeted experimentation, and in-service inspection considerations to demonstrate component performance and reliability under representative reactor conditions. The analysis identifies Sodium-cooled Fast Reactor (SFR) and High-Temperature Gas-cooled Reactor (HTGR) systems as reference configurations in terms of temperature, pressure, and chemical environment. Within these operating envelopes, dominant degradation mechanisms— including creep–fatigue interaction, flow-induced vibration, corrosion, and diffusion-bond deterioration—were evaluated to define test requirements. A comprehensive computationalexperimental framework is proposed to support life prediction and qualification activities. The framework couples high-fidelity structural-mechanics, thermal-hydraulic, and fluid-structure interaction models with accelerated degradation testing to produce a traceable linkage between microstructural evolution, mechanical performance, and remaining useful life (RUL). The approach adheres to established Verification, Validation, and Uncertainty Quantification (VVUQ) standards (ASME V&V 10/20; NUREG-2152) and incorporates a digital-twin architecture for continuous model refinement through data assimilation. The plan further outlines testing methodologies, including pre-test analyses, test-loop design parameters, and sensor placement strategies that maximize information yield while maintaining mechanistic fidelity. Complementary sections describe in-service inspection (ISI), on-line monitoring (OLM), and structural-health-monitoring (SHM) techniques applicable to compact HX geometries typical of advanced reactors. Collectively, these activities establish the technical foundation for demonstrating 40-60-year equivalent service life of advanced heat exchangers in support of the U.S. Department of Energy’s Advanced Reactor and Integrated Energy Systems programs. The forthcoming phase will execute the defined pre-test analyses, initiate hardware fabrication, and implement the integrated testing campaign to validate the proposed qualification methodology.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

A digital twin platform for building performance monitoring and optimization: Performance simulation and case studies

Advancements in sensor technology, data analytics, affordable compute, and communication infrastructure have paved the way for Digital Twin technology in optimizing building operations and controls. This study presents the development of an open and interoperable web-based Digital Twin platform for integrating diverse data streams and facilitating effective user interactions. The platform utilizes modern technologies for the web framework and time-series data management, ensuring scalability and responsiveness. The backend supports seamless integration of diverse data sources and emulators, incorporating data from building sensors and meters, external weather Application Programming Interfaces, and advanced EnergyPlus simulation models of the building and its energy systems including the Distributed Energy Resources that are formulated in Functional Mockup Units. A simulation case study was conducted with FlexLab, a test facility on Lawrence Berkeley National Laboratory campus. The case study includes normal operations, Distributed Energy Resource integration, and power outage scenarios, to illustrate the Digital Twin’s ability to provide critical insights into energy performance and thermal resilience. The results demonstrated the platform’s potential as a decision-support tool for optimizing building energy performance and enhancing resilience against extreme weather events. Future work will focus on deploying the Digital Twin platform to a real building for field validation, extending its capabilities to cover more scenarios such as bidirectional Electric Vehicle interactions, and enhancing user engagement.

EnergyPlus↗

Performance of a phonon-mediated kinetic inductance detector at the NEXUS cryogenic facility

Microcalorimeters that leverage microwave kinetic inductance detectors to read out phonon signals in the particle-absorbing target, referred to as kinetic inductance phonon-mediated (KIPM) detectors, offer an attractive detector architecture to probe dark matter (DM) down to the fermionic thermal relic mass limit. A prototype KIPM detector featuring a single aluminum resonator patterned onto a 1-gram silicon substrate was operated in the Northwestern EXerimental Underground Site (NEXUS) low-background facility at Fermilab for characterization and evaluation of this detector architecture’s efficacy for a DM search. An energy calibration was performed by exposing the bare substrate to a pulsed source of 470-nm photons, resulting in a baseline resolution on the energy absorbed by the phonon sensor of 2.1 ± 0.2 eV, a factor of two better than the current state of the art, enabled by quasiparticle lifetimes extending up to 6.5 ms. However, due to the subpercent phonon collection efficiency, the resolution on energy deposited in the substrate is limited to σ E = 318 ± 29 eV. We further model both the signal pulse shape as a function of device temperature to extract quasiparticle lifetimes, and the observed noise spectra.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Characterizing the Performance of Fission Chambers for Local Neutron Flux and Spectrum Measurement

Three fission chambers were tested at The Ohio State University Research Reactor (OSURR) to evaluate fission chambers for neutron flux and spectrum measurements. Two of the fission chambers are commercial Photonis CFUR43 fission chambers—one utilizing highly enriched uranium-235 fissile deposits for thermal neutron detection and the other with highly depleted uranium-238 for fast neutron detection. This experiment was also performed in collaboration with French Alternative Energies and Atomic Energy Commission (CEA) with CEA suppling a uranium-235 loaded fission chamber built from the Photonis CFPR CE8/9 kit. The fission chambers were irradiated in a movable 6.5 inch dry tube at reactor powers of 50 kW, 200 kW, and 450 kW at ambient temperature and at 350°C. While all sensors demonstrated good linear sensitivity to reactor power, a leakage current of 6 nA was measured for the CFUR43 detectors. Additionally, the measured signal ratios of the two CFUR43 detectors did not match the theoretical values and are subject to further investigation on individual signal contributors.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Characterization of Transition Edge Sensors for the Simons Observatory

The Simons Observatory is building both large (6 m) and small (0.5 m) aperture telescopes in the Atacama Desert in Chile to observe the cosmic microwave background CMB radiation with unprecedented sensitivity. Simons Observatory telescopes in total will use over 60,000 transition edge sensor (TES) detectors spanning center frequencies between 27 and 285 GHz and operating near 100 mK. TES devices have been fabricated for the Simons Observatory by NIST, Berkeley, and HYPRES/SeeQC corporation. Iterations of these devices have been tested cryogenically in order to inform the fabrication of further devices, which will culminate in the final TES designs to be deployed in the field. The detailed design specifications have been independently iterated at each fabrication facility for particular detector frequencies. We present test results for prototype devices, with emphasis on NIST high frequency detectors. A dilution refrigerator was used to achieve the required temperatures. Measurements were taken both with 4-lead resistance measurements and with a time-domain Superconducting Quantum Interference Device (SQUID) multiplexer system. The SQUID readout measurements include analysis of current versus voltage (IV) curves at various temperatures, square wave bias step measurements, and detector noise measurements. Lastly, normal resistance, superconducting critical temperature, saturation power, thermal and natural time constants, and thermal properties of the devices are extracted from these measurements.

47 OTHER INSTRUMENTATION↗

PyJMAK: An Open-Source Python Toolkit for Modeling Solid-State Metallurgical Phase Transformations

Accurate prediction of metallurgical phase transformations is an essential basis for autonomous optimization and rapid part qualification. Several methods can be used to estimate the evolution of phase fractions such as JMAK kinetics-based models, phase-field models, thermodynamic models, and data-driven machine learning models. Thermodynamic and phase-field-based methodologies solve multiphysics equations requiring numerous calibration parameters and significant computational resources. As a result, the computation domain is limited to a point or on order of micron-meters. The data-driven models rely on large datasets from experiments and simulations. While the JMAK model only provides information about phase fraction evolution, it can predict this evolution in near real-time using thermal history and thermodynamic data without restriction on the domain. JMAK models have been popularly used by researchers to model phase transformations occuring during additive manufacturing or over arbitrary temperature profiles. Commercial proprietary software such as Abaqus and Ansys or closed-source in-house implementations offer the ability to model JMAK based kinetics to predict phase transformation. However, these software packages are not open-source or freely available for use and development in conjunction with manufacturing machines, sensors, and machine learning algorithms. In addition, the use of the model is restricted by a license token. In contrast, given temperature profiles at multiple points in the domain, this Python-based PyJMAK model can compute phase evolution in parallel due to its stand-alone modular, voxel-based structure, and it can be executed on high-performance computing resources without any license restrictions.

Prabhune, Bhagya [Oak Ridge National Laboratory (O↗