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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.

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At least 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Effects of Build Orientation and Heat Treatment on Neutron Irradiation Hardening in Inconel 625 Fabricated via Laser Powder Bed Fusion

Various Inconel 625 coupons fabricated via Laser Powder Bed Fusion (L-PBF) were neutron irradiated using the inside reflector of the reactor at the University of Missouri Research Reactor (MURR). Effects of build orientation and heat treatment on neutron-induced hardening were investigated by inspecting L-PBF samples built vertically or at a 45º angle in the following heat-treated conditions: as-built (no heat treatment), 700 ºC for 1 hour, 900 ºC for 1 hour, and 1050 ºC for 1 hour. The microhardness results of L-PBF samples before and after neutron irradiation were compared with traditional wrought Inconel 625. All samples underwent an irradiation flux of 6.61 x 1013 neutrons/cm²/s for 310 hours for an estimated damage of 0.012 dpa. Results indicate that as-built L-PBF specimens are less prone to radiation hardening relative to their wrought counterparts. As-printed diagonal specimens were shown to harden by 8% as compared to 1.2% hardening in as-printed vertical specimens.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Assessing laser powder bed fusion system geometric errors through artifact-based methods

Additive manufacturing (AM) machines have developed more rapidly than standardized frameworks needed for the qualification of their geometric capabilities. While some manufacturer-specific methods exist to test capabilities and perform some calibration tasks, standardization efforts have only recently been undertaken in the form of ISO/ASTM 52902. In this study, the recommended methodology prescribed by the standard was implemented by building geometric artifacts with a laser powder bed fusion (LPBF) system and performing dimensional inspection with a coordinate measurement machine (CMM), amongst other methods. Typical dimensional capabilities of the LPBF system are identified and commentary is made on applying metrology methods, detecting geometric error, and diagnosing base causes in the LPBF system. In doing so, favored metrology practices and measurement analysis methods auxiliary to the standard are proposed. Artifact measurements were used to characterize beam positioning error and beam offset error. Methods for decoupling the effects of error sources are proposed. Difficulties in the inspection of AM components are identified, and the effects of various CMM measurement strategies are evaluated. Insights on the application of the new standard are presented, along with commentary as to its fitness for the LPBF process.

Berez, J.↗
DOE OSTI2022

Risk-Informed Operations and Maintenance Decision Making Using Deep Reinforcement Learning

A challenge for operating nuclear power plants is the significant cost of operations and maintenance, at times consuming up to 66% of annual operating costs. This project aims to build a framework for a risk-informed asset-management tool that integrates inspections, repairs, spare-part inventory, supply chain, and business choices to lower overall O&M costs. Our approach uses a combination of data-driven modeling and deep reinforcement learning to create and implement optimal maintenance policies for the existing nuclear fleet, as well as new advanced reactors. The creation of an asset management tool that uses these advanced methods will give operators new capabilities to help reduce the burden of O&M spending in nuclear power plants.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2026

WM26 Paper Multi-Robot Collaboration for Hazardous Environments

Hazardous nuclear and industrial facilities are rarely designed for robots. Work in these domains demand precise manipulation and robust mobility in cluttered, constrained spaces where off-the-shelf platforms struggle and “one-size-fits-all” machines become costly and complex. Idaho National Laboratory (INL) is developing an autonomous, multi-robot inspection system that coordinates task-specific platforms rather than relying on a single omni-tool robot. An electric truck serves as a power and compute hub for a custom manipulator co-developed with Florida International University (FIU), a commercial mini crawler, a pan–tilt–zoom camera, and a Nexxis Argus LiDAR mapping system. Working in concert, these robots generate spatial, radiation, and temperature maps of the pit environments at the Hanford Waste Tank Farms. These systems will capture visual records and environmental telemetry to allow for analysis post inspection. The system architecture uses Robot Operating System 2 (ROS 2) for publish/subscribe integration, NVIDIA Isaac Sim and Unity for simulation and visualization, and algorithms such as NVBlox to fuse data into unified 3D overlays. This robot-agnostic approach reduces operator burden by enabling autonomy across heterogeneous platforms and lets each robot be used where it is strongest. Having autonomous functions means operators don’t have to fully control multiple different components. The ease of use could allow for more widespread adoption of advanced robotics at waste management sites that see continued use. By coordinating simpler, purpose-built mechanisms, the approach lowers design and manufacturing complexity, reduces capital risk in contaminated settings, and improves controllability for complex inspection and manipulation tasks. We present the architecture, early results, and lessons learned from building and deploying this coordinated multi-robot system, with the goal of accelerating safe, cost-effective adoption of advanced robotics at waste-management sites.

42 - ENGINEERING↗
DOE OSTI2022

Assessing the New Home Market Opportunity: Case Study and Cost Modeling for Solar and Storage in 2030

Residential solar and storage markets are growing in the United States. With approximately 1 million new homes constructed every year, this represents a significant opportunity for solar and storage installations. Some homebuilders have begun to build new homes with solar and storage included as a standard offering. It is not clear how solar and storage is incorporated into the new construction process and at what cost. Further, it is unclear what barriers or opportunities exist to scale this model nationwide. To fill this gap in the literature, this research conducts a case study of Mandalay Homes' new solar and storage community in Arizona to gather lessons learned. From this foundation, we further generate a set of pathways to reduce install costs and expand solar and storage market penetration in this sector. To model existing and 2030 solar and storage costs, we use the National Renewable Energy Laboratory's (NREL's) bottom-up cost model. This modeling is further informed by 12 interviews conducted with new home builders, solar contractors, and other subject matter expert organizations. Our case study analysis generated three key considerations for other homebuilders including: 1. Educating local permitting, inspection, and in some cases utility officials on solar and storage products, designs, and code compliant building practices may be required. The need for education may decline as more local governments and utilities review and approve solar and storage projects. 2. Incorporating solar and storage systems into the homebuilding process can add complexity and related coordination challenges. This does not need to result in home construction delays, but can result in costly contractor "dry runs" to construction sites. 3. Deploying solar and storage at the time of new construction has significant economies of scale, which can improve the value proposition of the systems. The case study, extant literature, and interviews were used to model both existing and future solar and storage installation costs at time of new construction. Here, we find three key cost reduction opportunities relating to solar and battery storage hardware, customer acquisition, and overhead. If future contractors can maximize the cost reduction opportunities outlined here, residential new construction costs could decline by 8 - 25% by 2030, depending on the modeled scenario. Though we expect costs to decline through 2030, it is unclear which of these scenarios may ultimately appear. Interviewees further identified a variety of barriers across each cost category that could temper the savings shown here. At the same time, interviewees described several pathways to scale the new construction solar and storage market, beyond installation cost savings. Interviewees confirmed that changes in finance, rate design, resilience policies, deployment mandates, and DER aggregation could all support more market adoption than seen today. These findings suggest that there are significant opportunities to expand new construction markets and this research can serve as a baseline to assess progress in this segment through 2030.

14 SOLAR ENERGY↗
DOE OSTI2025

Determining Drying Conditions to Mitigate Hanford Transfer Line Corrosion

Radioactive waste is stored in underground, carbon-steel double-shell tanks at the Department of Energy Hanford site.1,2,3 The underground transfer lines are used to transfer the waste between the tanks and other assets at the Hanford tank farm facilities. The transfer lines constructed before 1990 are pipe-in-pipe design with most of the lines having carbon steel carrier pipe and carbon steel encasements. The lines constructed after 1990 have a stainless-steel carrier with a carbon steel encasement. The carrier lines, which are in contact with the waste, provide a critical confinement function, while the encasements provide secondary containment to reduce the risk of a release and contamination to the environment. In 2022, a visual inspection of the annulus between the encasement and the carrier for one of the pre-1990 transfer lines revealed standing liquid in contact with the carrier pipe. Additionally, a significant build-up of corrosion products on the exterior of the carrier pipe and the interior of the encasement pipe was observed. To assess the extent of condition, borescope inspections were performed in the encasement space of additional transfer lines in the facility to provide a baseline. The inspection revealed that of the lines inspected, 29 had either moisture present or evidence that moisture had been present in the past (e.g., waterline corrosion where the pipe had been exposed to standing water). Additional inspections indicated several instances of pitting corrosion on the interior of the encasement and exterior the carrier transfer lines. An image of the carrier pipe with several pits is presented in Figure 1(a) and the profiled image of the transfer line section along with the pit depths are presented Figure 1(b). As seen in the figure, the deepest pit was 73 mils on the pipe section. These lines were designated as “do-not-use” until further compensatory actions are implemented to return the lines to service.

Shukla, Pavan K. [Savannah River National Laborato↗
DOE OSTI2021

Aerosol-Based Method Seals the Deal for Tighter New Homes

What if an aerosol-based sealing method could tighten new home envelopes more quickly and effectively than traditional sealing methods? The method involves pressurizing an entire building while dispersing an aerosol sealant "fog" to the building interior. As air escapes the building through leaks in the envelope, sealant particles are carried to the leaks where they make contact and stick, sealing the leaks. A standard blower door and connected laptop facilitate the sealing process and provide real-time feedback and a permanent record of the sealing. The technology is thus capable of simultaneously measuring, locating, and automatically sealing leaks in a building. In fact, hundreds of linear feet of narrow leaks can be sealed simultaneously, reducing the time needed for manual inspection and sealing. To investigate the use of this method in new homes, the Center for Energy and Environment and partners worked with builders who performed the technique on 11 homes in California and 15 homes in Minnesota.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2020

TWF Waste Container Intra-Facility Transfer and Outgoing Shipment

This procedure provides instructions for the inspection and transfer of Transuranic (TRU) Waste containers within the Transuranic Waste Facility (TWF) (Waste Storage Buildings [WSBs], Characterization Waste Storage Building [CWSB]) and Characterization Trailers. This also includes the preparation to transfer to other LANL facilities. Performance of this procedure meets the requirements of SR 4.2.1.1, 4.2.1.2, 4.2.1.4, 4.2.1.5, 4.3.4.1, SAC 5.9.1, SAC 5.9.3 and AC 5.8.13 2nd bullet, as well as requirements set forth in the Los Alamos National Laboratory (LANL) Hazardous Waste Facility Permit (HWFP).

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

EnergyPlus-MCP: A model-context-protocol server for ai-driven building energy modeling

Traditional building energy modeling with the EnergyPlus building performance simulation engine requires domain expertise, programming skills, and intensive manual efforts limiting its effective adoption. This paper introduces EnergyPlus-MCP, the first open-source Model Context Protocol (MCP) server specifically designed for EnergyPlus simulation workflows, establishing a new foundational infrastructure for AI-driven building energy modeling. The MCP server implements a layered architecture with 35 specialized tools spanning model management, editing and analysis, HVAC and other systems configuration inspection, and simulation execution, enabling Large Language Models to interact with EnergyPlus through conversational interfaces. The server addresses critical workflow barriers by automating model validation, streamlining energy efficiency measures modification, and providing intelligent output management with interactive visualization. Through practical demonstrations using a multi-zone building retrofit analysis, we show how the EnergyPlus-MCP server significantly reduces manual efforts while maintaining full simulation rigor. By providing accessible natural language interfaces to sophisticated building energy analysis, this approach enables scalable deployment of simulation expertise across public and private organizations, educational institutions, and research teams, fundamentally transforming traditional building energy modeling practices.

AI↗
DOE OSTI2026

Draft ASME Code Case to qualify L-PBF 316H material for Section III, Division 5 applications

This report documents the AMMT program’s development and submission of a draft ASME Code Case to qualify Laser Powder Bed Fusion (L PBF) Type 316H stainless steel for Section III, Divi-sion 5 Class A and SM high temperature nuclear applications. It summarizes the technical basis, the comprehensive high temperature mechanical test database assembled between 2023–2026, and the proposed code language and qualification framework submitted to ASME. The work was co-ordinated across multiple national laboratories and leverages prior ASME efforts to integrate additive manufacturing into the Boiler & Pressure Vessel Code. The body of the report describes the experimental database and analysis supporting the Code Case: tensile, creep, fatigue, creep fatigue, and thermal aging tests collected from multiple additive manufacturing sites, machine types, and powder lots, with material processed by a solution anneal heat treatment. The dataset — including both full size and subsized specimens and tests oriented parallel and perpendicular to build direction — shows limited tensile anisotropy, tensile properties comparable to wrought 316H, creep strength within the scatter of wrought material, but markedly reduced creep ductility above about 650 °C associated with rapid σ phase formation in L PBF microstructures. The draft Code Case itself prescribes a staged qualification model (manufacturing process qualification, component qualification, and per build witness testing), treats L PBF components as equivalent to Type 316 weld metal for design and inspection, and requires mechanical, chemical, and metallographic controls tied to ASTM/ISO 52946. Key acceptance criteria include tensile tests within a 90% prediction interval of the AMMT dataset, a creep fatigue screening test adapted from ASME Section III, Division 5, Subsection HB, HBB 2800 but with the cycle acceptance reduced to 100 for L PBF material, and double volumetric inspection of production components. The report concludes that the present data support treating L PBF 316H as analogous to conventional fusion weld metal for Division 5 design and inspection, while highlighting important caveats: the σ phase driven loss of creep ductility above ~650 °C, preliminary indications of enhanced creep fatigue sensitivity in some lots, and remaining gaps in long term aging and additional cyclic testing. Recommended next actions include completing outstanding cyclic and long duration creep/aging tests on the solution annealed condition, supporting inclusion of the 316H chemistry and heat treatment in ASTM/ISO 52946, and continuing engagement with ASME and NRC during balloting and review to enable industry adoption.

Messner, Mark C. (ORCID:0000000200404385)↗
DOE OSTI2021

Rapid Quality Assessment in Additive Manufacturing: New Procedure Accelerates Build Quality Assessment. White paper

Accelerated growth of the additive manufacturing (AM) industry in recent years is accompanied by a rising need for methods to quickly assess quality at-scale. Current practices for quality inspection include nondestructive test methods and destructive testing of witness coupons, which are artifacts built alongside the actual part. However, these methods can be costly and time-consuming. Recognizing this need, the Additive Manufacturing Center of Excellence (AM CoE) initiated a project led by its partner, Auburn University, to develop rapid testing procedure using asbuilt samples tested in torsion to quantitatively assess build quality. The presented work developed a rapid testing procedure using as-built samples tested in torsion to quantify small variances for assessing build quality.

42 ENGINEERING↗
DOE OSTI2021

Classifying Seyfert Galaxies with Deep Learning

The traditional classification for a subclass of the Seyfert galaxies is visual inspection or using a quantity defined as a flux ratio between the Balmer line and forbidden line. One algorithm of deep learning is the convolution neural network (CNN), which has shown successful classification results. We build a one-dimensional CNN model to distinguish Seyfert 1.9 spectra from Seyfert 2 galaxies. We find that our model can recognize Seyfert 1.9 and Seyfert 2 spectra with an accuracy of over 80% and pick out an additional Seyfert 1.9 sample that was missed by visual inspection. We use the new Seyfert 1.9 sample to improve the performance of our model and obtain a 91% precision of Seyfert 1.9. These results indicate that our model can pick out Seyfert 1.9 spectra among Seyfert 2 spectra. We decompose the Hα emission line of our Seyfert 1.9 galaxies by fitting two Gaussian components and derive the line width and flux. We find that the velocity distribution of the broad Hα component of the new Seyfert 1.9 sample has an extending tail toward the higher end, and the luminosity of the new Seyfert 1.9 sample is slightly weaker than the original Seyfert 1.9 sample. This result indicates that our model can pick out the sources that have a relatively weak broad Hα component. In addition, we check the distributions of the host galaxy morphology of our Seyfert 1.9 samples and find that the distribution of the host galaxy morphology is dominated by a large bulge galaxy. In the end, we present an online catalog of 1297 Seyfert 1.9 galaxies with measurements of the Hα emission line.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2022

Vision-based inspection of prefabricated components using camera poses: Addressing inherent limitations of image-based 3D reconstruction

Modular construction can lead to additional cost overruns and delays when a defect is found on the construction site and is not easily repairable. Researchers have developed various methods that use image-based 3D reconstruction for quality assessment, but they have inherent limitations, such as inconsistency and dealing with surfaces with reflectivity and limited visual features. Therefore, this paper presents a vision-based quality assessment method using cameras for prefabricated components by addressing these limitations. Specifically, this paper proposes a novel quality inspection method with sub-millimeter accuracy using cameras focused on leveraging camera poses (as opposed to 3D point clouds that are often not consistent in quality) from the image-based 3D reconstruction. The 3D point estimation by computing triangulation was used for achieving accurate measurement. The proposed method is validated using six different variances and two case studies – an aluminum pipe with a reflective surface and a fabricated concrete column. Furthermore, the results demonstrate the accuracy and effectiveness of the proposed method.

42 ENGINEERING↗
DOE OSTI2022

SolarAPP+ Pilot Analysis: Performance and Impact of Instant, Online Solar Permitting

The National Renewable Energy Laboratory (NREL) led a collaborative effort to develop the Solar Automated Permit Processing Plus (SolarAPP+), a no-cost solar permitting software solution to address residential solar photovoltaic (PV) permitting resource constraints and streamline solar adoption processes among authorities having jurisdiction (AHJs). The SolarAPP+ is an online portal that automates permit plan review, enabling an instant permit approval process for code-compliant residential PV systems. Based on national model building, electrical, and fire codes, the SolarAPP+ automatically performs a compliance check of permit inputs against code requirements and produces an inspection checklist that can be used to verify installation practices, workmanship, and adherence to the approved design. NREL conducted a two-phase pilot with five participating AHJs and 16 solar contractors, spanning from November 2020 through December 2021, evaluating the ability of SolarAPP+ to deliver instant permits and its impact on four critical areas within each AHJ: permit review timelines; solar adoption timelines; AHJ time saved; and inspection results. The pilot confirmed that SolarAPP+ reduced permit review times to less than one day, reduced solar adoption timelines by an average of 12 days, saved an estimated 2,067 staff hours, and had comparable inspection results to those found in traditional permitting. The pilot further identified key lessons for improving SolarAPP+, including ways to streamline SolarAPP+ adoption, development of training resources, and expansion of supported products.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2020

TWF Waste Container Receipt, Inspection and Transfer to Storage

This procedure provides instructions for the receipt, inspection, and transfer to storage of Transuranic (TRU) Waste Containers and Pipe Overpack Containers (POC) within the Transuranic Waste Facility (TWF) (Waste Storage Buildings [WSBs] and Characterization and Waste Storage Building [CWSB]). Performance of this procedure meets the requirements of AC 5.8.9, AC 5.8.13 2nd Bullet, SAC 5.9.1, SAC 5.9.3, SR 4.2.1.1, 4.2.1.2, 4.2.1.5, 4.2.1.6, 4.2.2.1, 4.2.2.2, 4.2.2.3, 4.2.2.4, 4.2.3.1, 4.2.3.2, 4.2.3.3, 4.3.4.1, 4.4.1.1, 4.4.1.2 and 4.4.1.3.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

System and method for inspecting parts using dynamic response function

A system and method for the non-destructive testing of additively manufactured parts. An input mechanism excites with an excitation force (e.g., a vibration) an additive manufacturing build structure, which includes a part on a build platform, to induce a dynamic response in the part. An output mechanism (e.g., a non-contact transducer) senses the induced dynamic response in the part. A processor determines and examines the relationship between the response and excitation to identify an indication of a defect in the part, and communicates an alert if the indication is identified. The processor may compare the phase, magnitude, coherence, or time delay of the relationship to a reference relationship and/or may compare the modal frequency or the modal damping to a reference to identify a deviation greater than a pre-established threshold.

Hartwig, Troy Juan↗
DOE OSTI2020

Contaminant Migration Modeling to Support the In Situ Decommissioning of Hardened Nuclear Facilities - 20215

The decommissioning of hardened nuclear facilities provides a unique challenge in balancing current worker dose with exposure to future receptors and media. In situ decommissioning (ISD) is a cost-effective and safe option for the closure of such facilities but requires a detailed understanding of the threat that radioactive and hazardous constituents remaining in the facilities pose to groundwater and surrounding surface water. The Savannah River Site (SRS) extensively employs contaminant migration models within the decommissioning process to develop site-specific removal, grouting, and monitoring strategies in support of safe and effective final end states of nuclear facilities. This work discusses the use of contaminant migration modeling in the ISD process at SRS, including specific examples from the closure of P-Reactor and R-Reactor, Building 235-F, F-Canyon and F/H Laboratory Complex. Migration models developed during the closure of P-Reactor and R-Reactor were divided into four source areas: the reactor vessel, the process area, the disassembly basin, and the purification wing. Each source area was assigned a specific inventory and migration pathway and was then subject to varying hypothetical removal, capping, and grouting schemes. Modeling indicated that groundwater Maximum Concentration Limits (MCLs) might be exceeded if no action was taken for eleven and ten constituents of concern (COCs) at P-Reactor and R-Reactor, respectively. These exceedances could occur in as few as 200 to 500 years. Alternatively, the migration modeling demonstrated that the selected ISD actions reduced contaminant mobility which allowed for significant radioactive decay and resulted in fewer predicted exceedances of groundwater MCLs (five COCs for P-Reactor; eight COCs for R-Reactor). In response to the modeling results for P-Reactor and R-Reactor, effectiveness monitoring programs were developed to target contaminants, specific to each reactor, that may migrate to groundwater. Contaminant migration modeling also revealed that roof collapse was a large factor in the release of COCs to the environment, giving rise to roof improvements, and an inspection and vegetation control program to ensure roof stability over time. Contaminant migration modeling is also aiding in the closure planning for hardened facilities in F Area. Building 235-F housed the Actinide Billet Line, which produced Np-237 billets for irradiation in SRS reactors, and the Plutonium Fuel Form (PuFF) facility that produced Pu-238 heat sources for the space program. As a result of these missions, areas within Building 235-F contain considerable residual amounts of both Pu-238 and Np-237. Contaminant migration modeling of Building 235-F was originally performed in 2012 to identify the feasibility of ISD and the amount of radioactive material removal required to prevent the exceedance of groundwater MCLs. The original model indicated that a 60% reduction in the PuFF facility Pu-238 inventory could keep groundwater concentrations below standards, while Np-237 did not pose a threat to groundwater. However, updates to the model with an emphasis on source impact pathways revealed that, due to the orientation of the source areas relative to groundwater flow, no amount of reasonable removal of Pu-238 would keep groundwater concentrations below MCLs and that Np-237 could be a large contributor to localized MCL exceedances. With this insight, the refined 2019 model is being used to assist in the development of grouting plans specific to each facility source area, where bentonite may be utilized to slow the migration of Pu-238 and its daughter products from the PuFF facility and a reducing grout may decrease Np-237 transport by ensuring the nuclide remains in the less mobile +IV oxidation state. The beginning phases of contaminant migration modeling are underway for F-Canyon and associated facilities using lessons learned from the Reactors and Building 235-F. A contaminant migration pathway, similar to the pathway used for the reactor vessels, is being developed for the hot and warm canyons. The F-Canyon inventories are being spatially refined to identify specific and localized source zones, comparable to Building 235-F, that may impact groundwater. Contaminant migration modeling provides vital input within the ISD process, from facility investigation to post closure effectiveness monitoring, making it a valuable tool in the development of safe and effective end states for hardened nuclear facilities at SRS. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2022

AI-Enabled Robots for Automated Nondestructive Evaluation and Repair of Power Plant Boilers. Final Report

Boiler failure could cause loss of life and safety issues, cost hundreds of thousands of dollars in equipment repairs, property damage and production losses, and drive up the cost of electric power. Boiler maintenance is challenging and risky for inspectors working on scaffolding in confined hazardous spaces inside of a boiler and sometimes the space is hard to access. The operation is also time-consuming due to the large area of vertical structures for inspection and the tremendous effort needed for scaffolding. Recently, the use of robotics (e.g., drones and crawlers) in power plants for maintenance is growing rapidly. However, the existing robotics solutions show two notable technological gaps: no live repair capability, and no Artificial Intelligence (AI) for smart autonomy. The objective of this project is to develop an integrated autonomous robotic platform that is equipped with compact non-destructive evaluation (NDE) sensors to perform live inspection, operates onboard repair devices to perform live repair, and uses AI for intelligent data fusion and predictive analysis for automated and smart spatiotemporal inspection, analysis and repair of the furnace walls in coal-fired boilers. The approach to achieve the objective includes developing NDE sensors with signal processing techniques, designing and evaluating repair devices for robots based on fusion and solid-state technologies, and an autonomous robotic platform that can attach to and navigate on boiler furnace walls using magnetic drive tracks. The robot is also powered by AI to automate data gathering (e.g., 3D mapping and damage localization) and predictive analysis. This project has advanced the state-of-the-art by providing technological breakthroughs including compact NDE and repair tools for robots, AI capabilities for smart autonomy, and a robotic platform for automated boiler maintenance. This project has great potential to result in significant benefits including limiting or eliminating the need to send operators to assess difficult-to-access or hazardous areas, enabling automated live inspection and repair, avoiding time consuming scaffolding (especially for partial maintenance during unplanned outage), collecting comprehensive and well-organized data smartly, and avoiding or limiting the need for onsite or remote piloting technicians. The impacts can be tremendous in terms of the time and cost savings, reducing the risk for human operators, and increasing boiler reliability, usability, and efficiency. In addition, by developing the new technologies on the autonomous inspection and repair robot, by involving multiple undergraduate and graduate students working together with the faculty members on this project, and by generating knowledge and building up collaborations with industrial partners, this effort will significantly update the education capabilities, support long-term fundamental research, and maintain the leadership of Colorado School of Mines and Michigan State University in energy fields.

20 FOSSIL-FUELED POWER PLANTS↗