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Endoscopic inspection using a panoramic annular lens

The objective of this one year study was to design, build, and demonstrate a prototype system for cavity inspection. A cylindrical view of the cavity interior was captured in real time through a compound lens system consisting of a unique panoramic annular lens and a collector lens. Images, acquired with a digitizing camera and stored in a desktop computer, were manipulated using image processing software to aid in visual inspection and qualitative analysis. A detailed description of the lens and its applications is given.

Gilbert, John A.↗

Final Technical Report (FTR) - DE-EE0009084: Prefabricated Construction: Guidance, Technical Assistance, and Virtual Inspections

This final technical report summarizes research, case studies, and resources developed from 2020–2025 on prefabricated construction and remote virtual inspections. It documents key findings on benefits, challenges, and best practices, highlights examples from multiple states, and provides guidance to support wider adoption of these innovations in the construction sector.

99 GENERAL AND MISCELLANEOUS↗

NASA Marshall Space Flight Center Tools for Human Factors Engineering Assessments for Safe Sls Worksites

NASA Marshall Space Flight Center (MSFC) Human Factors Engineering (HFE) Team is implementing mockup fabrication, virtual reality (VR) and motion capture (MoCap) into HFE analyses of SLS worksites through its Virtual Environments Lab (VEL). MSFC HFE Team is responsible for the Space Launch System (SLS) worksite analyses of the integration activities performed at the Kennedy Space Center (KSC). With a wide variety of tasks, it is important to verify that SLS can be safely integrated at KSC early in the design process. If the ground support crew cannot safely complete the tasks, redesign efforts must be implemented. MSFC HFE is responsible for verification through methods such as drawing inspection, observation of tasks performed, and building physical mockups. There is a need, however, for a faster analysis early in the process that can impact design safety before drawings are finalized. This need is addressed through MSFC’s VEL.

Andrews, Tanya↗

The Effect of Laser Scan Strategy on Distortion and Residual Stresses of Arches Made With Selective Laser Melting

The NASA Marshall Space Flight Center (MSFC) is developing Additive Manufacturing (AM) - both in-space AM for on-demand parts, tools, or structures, and on-earth AM for rapid, reduced-cost, small volume production of complex space-flight hardware. Selective Laser Melting (SLM) is an on-earth AM technology that MSFC is using to build Alloy 718 rocket engine components. An understanding of the SLM-718 material properties is required to design, build, and qualify these components for space flight. Residual stresses and are of particular interest for this AM process, since SLM is a series of approximately 100 micron-wide welds, where highly non-linear heating and cooling, severe thermal gradients and repeated thermal cycling can result in high residual stresses within the component. These stresses may cause degraded material properties, and warp or distort the geometry of the SLM component. The distortions can render the component out-of-tolerance when inspected, and even interrupt or halt the build process if the warped material prevents the SLM machine from operating properly. The component must be scrapped and re-designed, which is time consuming and costly. If residual stresses are better understood, and can be predicted, these effects can be mitigated early in the component's design. the compressive residual stresses in the z-direction were highest in the chess sample, followed by island then continuous. This may be due to the binding nature of the segments

Bagg, Stacey D.↗

In-Situ Process Monitoring, Synchronization, and Mapping Laser Powder Bed Fusion Builds of Ti6Al4V

The use of in-situ process monitoring is of interest to lower the cost of inspection for the qualification of laser powder bed fusion (LPBF) parts. Precise monitoring of the LPBF-AM build process constitutes a multi-scale and multi-discipline task. There are several significant challenges to the in-situ approach: the synchronization of sensor signals to process steps, the physical interpretation and classification of sensor signals, managing very large datasets, and comparing the inputs with the observed monitoring signals. At NASA Langley Research Center, a configurable architecture additive testbed has been developed to monitor the build process with synchronized sensors. The philosophy and method adopted for the synchronization of the cameras with laser power & position Ti-6Al-4V LPBF are described. The synchronized in-situ monitoring signals are compared with ex-situ nondestructive inspection and optical microscopy observations. Such comparisons permit a better understanding of how the sequential process actions of LPBF-AM can affect build quality.

Laser Powder Bed Fusion↗

Material Inspectability Assessment Related to Lunar Construction Technology Development

For the building of lunar structures on the Moon using lunar regolith-based construction materials, ensuring their structural integrity and employing methods optimal for such tasks is crucial. In this technical memorandum (TM) the detectability of simulated void defects in a cementitious-based lunar construction material is compared between different nondestructive evaluation (NDE) methods, especially methods which have potential to be developed into space qualified instruments. Primarily, simulated voids, introduced during fabrication as foam spheres, were used for this evaluation. Furthermore, smaller, unintended void defects were used to assess the detectability. The results highlights trade-offs between the NDE methods in terms of detection limit, correct size indication, penetration depth, and potential for reduction in size, weight, and power (SWaP).

Nondestructive Evaluation↗

Microstructure and Elevated Temperature Flexure Testing of Tungsten Produced by Electron Beam Additive Manufacturing

Abstract Due to their superior high-temperature thermomechanical capabilities, sputter erosion durability, and excellent resistance to hydrogen isotopes, tungsten materials have garnered significant interest in fusion nuclear applications. However, low room-temperature ductility and complex machining strategies present significant challenges for traditional fabrication. Electron beam powder bed fusion (EB-PBF) shows promise in manufacturing pure tungsten via high thermal energy input, elevated build temperature, and a tightly controlled high-vacuum environment. This work explores the process, structure, and property relationship of pure tungsten fabricated by EB-PBF, where 99.8% relative density was achieved with reduced cracking by isolating the build substrate and optimizing the print parameter suite. Optical and electron imaging revealed that the microstructure contained equiaxed grains along the build direction, with subgrains present in all inspected grains. Flexural testing at ambient and elevated temperatures demonstrated high ductility at 900°C and flexural strength of 470 MPa at room temperature of additively manufactured tungsten.

Zhang, Haozhi↗

Residential Building Energy Efficiency Field Studies: Low-Rise Multifamily

In recent years, the U.S. Department of Energy (DOE) has conducted a series of research studies to validate energy efficient building technologies in the field. Much of the work has focused on single-family construction, and some has also addressed commercial energy codes. The work detailed in this DOE-funded study (EE0007616) focuses on low-rise multifamily buildings (three stories or fewer above grade) in various regions of the United States, and reports on how state-level building codes are being implemented, both in terms of observed characteristics and also in terms of estimated energy impacts. Nearly 100 buildings across four states—Illinois, Minnesota, Oregon, and Washington—were sampled, which represent a range of climate types from mild temperature to very cold continental. Both common entry and outdoor entry buildings were included, and a parallel research project evaluated envelope air tightness and current still-evolving air tightness testing methods. Finally, a set of structured interviews of building designers and other relevant professionals was carried to out to gain more insight into this market. To the greatest extent possible, the methodology developed under the project for low-rise multifamily buildings mirrored the approach established by Pacific Northwest National Laboratory (PNNL) for single-family residential buildings (https://www.energy.gov/eere/buildings/downloads/residential-building-energy-code-field-study). This included the general approach to sampling, recruitment, and data collection, as well as data analysis and presentation. The range of permitting dates for the sites encompassed two energy code cycles in most regions. All states in the study had adopted a variation of the International Energy Conservation Code (IECC) for the structure of their state code. The low-rise multifamily occupancy presents a hybrid building type: most of the building’s conditioned floor area was covered by the residential chapter of the code while portions of the building (such as corridors and common spaces) fell under the commercial code chapter. The key items assessed in this work were: Building Shell—exterior wall insulation, ceiling insulation, foundation insulation, windows. Common Areas—HVAC and lighting. Living Units—lighting, ventilation. A few items were not assessed in detail, given their relative paucity in this occupancy type; these included duct leakage, pipe insulation, and hot water circulation controls. Building characteristics were collected via a combination of architectural, mechanical, electrical, and plumbing plan reviews and field inspections, and entered into a spreadsheet-based tool that was later queried to build a database. Data went through quality control both upon arrival and via a later semi-automated review and assurance process. Most of the data are presented graphically so that the reader can quickly assess compliance with the applicable energy codes (both by state and by code year). As a final step, EnergyPlus™ simulations were created for all buildings in the study to estimate both the as-found energy use intensity (EUI) and the energy and CO 2 that could be saved if features that were found to not meet code minimums were brought up to code. The savings estimates were tabulated for each of the four states in the study. The research team found that the single-family approach was largely applicable to low-rise multifamily buildings. This applies to both the data collection and the prototype EUI analysis. Most of the occupied space is living units and falls under residential energy codes, and many characteristics use similar envelope construction and relatively straightforward mechanical systems and lighting. One of the most challenging aspects of this work was to build an effective spreadsheet-based data collection instrument that could allow efficient collection of both building plan and field data. The research team is of the view that other methods could be equally effective if the work is done carefully with diligent quality control. The primary findings for the work center around the thermal envelope and mechanical systems and lighting at the sites: For thermal envelope components, the majority of buildings met or were better than the prescriptive code.This suggests that building designers and builders are aware of code requirements. In some cases, surveyed buildings were designed to qualify for energy efficiency certification programs. These buildings made up at least 20% of sampled buildings in each state. Almost all buildings met mechanical system efficiency requirements (for both living units and common areas). In some cases, sites employed systems that were considerably more efficient than required by the applicable energy code. Dwelling units had a majority of high-efficacy lighting, often in excess of the state’s residential code requirements. While high-efficacy fixtures were also typical in common areas (corridors and stairwells), lighting power densities (LPDs) in these areas were sometimes higher than levels dictated by the applicable part of the state commercial energy code. The simulation models run on a series of low-rise multifamily prototypes, informed by a composite of the field data collected, calculated annual EUIs of between 20 and 50 kBtu/ft2-yr, with the range representing the effects of both building characteristics and building location (climate zone). A detailed process (based on simulations of prototype buildings) was used to estimate the amount of avoided energy use that would occur if 100% adherence to energy codes were attained. The results indicated modest savings are attainable for items such as window thermal performance and common area lighting. The result is overall only a modest potential for additional energy savings, averaging about 10% of EUI.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

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

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

42 ENGINEERING↗

Characterization of build parameters and microstructure in low heat input WAAM of Ni-based superalloy Haynes 282

Conference paper for 2024 10th International Conference on Advances in Materials, Manufacturing & Repair for Power Plants. Ni-based superalloy Haynes 282 is a prime candidate for advanced power generation systems due to its superior fabricability, weldability, and high-temperature performance. Additive manufacturing offers potential cost and time savings for gas turbine components. Wire-arc direct energy deposition can create large components but often requires post-processing treatments, such as hot isostatic pressing (HIP), to address porosity. This study explores a low heat-input, high deposition rate GMAW process to achieve fully dense Haynes 282 without HIP. Twenty-one blocks were deposited, varying travel and wire feed speeds. Initial analysis (visual inspection, microstructural examination, and CT) revealed the impact of build parameters on internal porosity and defects. Scanning electron microscopy provided insights into structural heterogeneity and microstructural properties. Related journal article can be found at https://doi.org/10.31399/asm.cp.am-epri-2024p0001.

Adam, Benjamin↗

Development of a medium-duty stoichiometric diesel micro-pilot natural gas engine

Fueling a compression-ignition engine with premixed natural gas offers the potential to combine a clean-burning, low-carbon fuel with a high compression ratio, high-efficiency engine. This work describes the development of a multi-cylinder 6.7 L diesel engine converted to run stoichiometric diesel micro-pilot/ natural gas premix combustion with a maximum diesel contribution target of 5% of the total fuel energy and a three-way catalyst aftertreatment system. Results are given by comparing the stoichiometric combustion to the diesel baseline operation, showing combustion characteristics differences, including the rapid two stage heat release. A high load output of 23 bar brake mean effective pressure was obtained with diesel-like brake thermal efficiency of 41%. This operating condition enabled a brake specific CO 2 emissions reduction of up to 25% when compared to diesel. It was observed that the low load output is limited by combustion stability when operated at stoichiometric condition. The three-way catalyst is observed to run at peak efficiency with an equivalence ratio of 1.01. Injector fouling was observed through the inspection of the nozzle and its internal parts, indicating carbon build-up similar to that seen in injector coking mechanisms. A comparison of the developed engine to other engine technologies is given, showing that the diesel micro-pilot natural gas engine performance is in good standing among other diesel and gas engines in the market.

Engineering↗

In-Space Inspection Technologies Vision

Purpose: Assess In-Space NDE technologies and needs - current & future spacecraft. Discover & build on needs, R&D & NDE products in other industries and agencies. Stimulate partnerships in & outside NASA to move technologies forward cooperatively. Facilitate group discussion on challenges and opportunities of mutual benefit. Focus Areas: Miniaturized 3D Penetrating Imagers Controllable Snake-arm Inspection systems Miniature Free-flying Micro-satellite Inspectors

Studor, George↗

Structural Health Monitoring of Large Structures

This paper describes a damage detection and health monitoring method that was developed for large space structures using on-orbit modal identification. After evaluating several existing model refinement and model reduction/expansion techniques, a new approach was developed to identify the location and extent of structural damage with a limited number of measurements. A general area of structural damage is first identified and, subsequently, a specific damaged structural component is located. This approach takes advantage of two different model refinement methods (optimal-update and design sensitivity) and two different model size matching methods (model reduction and eigenvector expansion). Performance of the proposed damage detection approach was demonstrated with test data from two different laboratory truss structures. This space technology can also be applied to structural inspection of aircraft, offshore platforms, oil tankers, ridges, and buildings. In addition, its applications to model refinement will improve the design of structural systems such as automobiles and electronic packaging.

Kim, Hyoung M.↗

Future of Condition Based Maintenance at Stennis

This study seeks to understand the current state of condition based maintenance (CBM) at Stennis Space Center and set a bench mark for the future expansion of the CBM program. Condition based maintenance is the idea of maintaining an asset upon decreasing performance or when a failure is impending instead of at some arbitrary time regardless of condition. Special attention was paid to remote sensing and monitoring of assets around the center to cut maintenance costs and extend overall operational lifetime of those assets. It was found that 55 percent of the categories of assets which could actually utilize a remote CBM program are currently being partially monitored. CBM solutions that have been investigated and proposed for future deployment cover areas such as building integrity, oil analysis, power line and water pipe inspection.

George, Cory A.↗

Interesting Graphite Facts

Interesting facts about graphite. Graphite within HTRs and how long they will last, potential issues prediction, model building to predict expected behavior, and frequent and thorough inspection and monitoring strategy.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA’S Current Efforts and Applications of NDE to Improve Space Flight Safety

National Aeronautics and Space Administration (NASA) continues to push the boundary of manned flight. Current mission profiles include flights to the moon and mars. Many of these missions require advance manufacturing and planned off planet resource utilization. As NASA continues to develop highly advance materials and manufacturing techniques to meet these mission profiles, inspection of these increasingly complex parts has had to evolve as well. Additive manufacturing is coming to the forefront as a primary manufacturing technique but offers unique challenges when inspection and certification are required. NASA has been working diligently to be a leader in developing and utilizing inspection techniques capable of inspecting these highly advanced parts. Additionally additive manufacturing techniques can also be used to build parts in space and provides a vehicle for in-situ resource utilization for off world missions. As NASA and its commercial crew partners move forward inspection techniques will need to continue to advance to ensure safe manned space flight. In this talk NASA will highlight many of the advanced nondestructive evaluation efforts going on across the agency. As well as highlights for points of infusion for helping NASA meet it’s future missions.

NDE↗

NASA's Office Safety Mission Assurance Efforts to Improve Non-destructive Evaluation Methods for Additive Manufacturing and In-Space Inspection

National Aeronautics and Space Administration (NASA) continues to push the boundary of manned flight. Current mission profiles include flights to the Moon and Mars. Many of these missions require advance manufacturing and planned off planet resource utilization. As NASA continues to develop highly advance materials and manufacturing techniques to meet these mission profiles, inspection of these increasingly complex parts has had to evolve as well. Additive manufacturing is coming to the forefront as a primary manufacturing technique but offers unique challenges when inspection and certification are required. NASA has been working diligently to be a leader in developing and utilizing inspection techniques capable of inspecting these highly advanced parts. Additionally additive manufacturing techniques can also be used to build parts in space and provides a vehicle for in-situ resource utilization for off world missions. As NASA and its commercial crew partners move forward, inspection techniques will need to continue to advance to ensure safe manned space flight. In this talk NASA will highlight many of the advanced nondestructive evaluation efforts going on across the agency, as well as providing highlights for points of infusion for helping NASA meet its future mission goals.

NDE↗

Powder Bed Fusion Laser Beam Metals Additive Manufacturing: Process Monitoring Approaches for Qualification and Certification

The use of in-situ process monitoring is of interest to lower the cost of inspection for the qualification of powder bed fusion laser beam metal (PBF-LB/M) additively manufactured (AM) parts. Precise monitoring of the PBF-LB/M AM build process constitutes a multi-scale and multi-discipline task. There are several significant challenges to the in-situ approach: the synchronization of sensor signals to process steps; the physical interpretation and classification of sensor signals; managing very large datasets; and comparing the inputs with the observed monitoring signals. At NASA Langley Research Center, a configurable architecture additive testbed has been developed to monitor the build process with synchronized sensors. The philosophy and method adopted for the synchronization of the cameras with laser power and position throughout a complex PBF-LB/M AM build will be described. The synchronized in-situ monitoring signals are compared with ex-situ nondestructive inspection, x-ray computed tomography (XCT). Such comparisons permit a better understanding of how the sequential process actions of LPBF-AM can affect build quality. The multi-scale and complex process of printing additively manufactured (AM) parts can have unexpected, but predictable, build conditions that result in material microstructure variability. This presentation will describe an additive manufacturing model-based process metric (AM-PM) computational method that is a fully parallel reduced order modeling approach developed to evaluate the evolution of AM processes. This method couples the known sequence of the AM process with a physically informed nearest neighbors’ calculation to map the conditions of a part-scale build. The result is a map of the build that is derived directly from build files or in-situ process monitoring sensors. The methodology of the approach will be described and mapped to the porosity observed from XCT for a complex PBF-LB/M build. Such comparative results develop understanding of how the sequential process actions can affect the PBF-LB/M AM build quality and microstructure variability.

Laser Powder Bed Fusion↗