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At least 541 records · Page 30

Imaging of Calibrated Defects in Additively Manufactured Materials: Pulsed Thermal Tomography Nondestructive Examination of Additively Manufactured Reactor Materials and Components

Additive manufacturing (AM, or 3D printing) for commercial nuclear energy applications is an emerging method for cost-efficient manufacturing aimed at replacing aging nuclear reactor parts and reducing costs for new construction. Known material flaws in AM include low-density regions consisting of non-sintered powder, which have to be detected to ensure the safety of long-term performance nuclear reactor components. Currently, limited options are available for nondestructive evaluation (NDE), either during or post manufacturing. As a solution to NDE of AM, we are developing pulsed thermal imaging which is non-contact, one-sided, and scalable to arbitrary size and shape of the AM parts. Pulsed thermography (PT) system utilizes a high intensity flash lamp to rapidly heat surface of sample, and a high sensitivity fast-frame megapixel infrared (IR) camera to capture data of surface temperature variations. The acquired data cube consists of a stack of surface temperature images taken at different times. Information about material internal defects is extracted by analyzing the data cube. This report provides results of preliminary performance evaluation of pulsed thermal imaging capability in detection of imprinted flaws in AM metallic structures. The flaws were introduced into AM parts as imprinted hemispherical low density regions, consisting of trapped un-sintered metallic powder. Specimens for developed for this study consisted of AM stainless steel 316 and Inconel 718 plates. The diameters of imprinted defects varied from 1mm to 8mm, and their depths below the plate flat surface varied between 1mm and 6mm. Pulsed thermal tomography (PTT) processes the measured data cube to obtain 3D reconstructions of material effusivity using a unique inversion algorithm developed at Argonne. PTT has been previously used in imaging of similar size flat bottom hole (FBH) simulated defects in stainless steel 316 and Inconel 718 specimens. In the study involving AM specimens, PTT imaging results have shown that 1mm-diameter defects located 1mm and 2mm below the surface of specimens were detectable. Larger size defects were detectable at greater depth. We also explored an alternative approach to detection of material flaws in PT data cube, which is using neural learning-based approach to blind source separation. Detection of small material defects requires finding features in the data cube which have signal contrast levels approaching sensitivity limit of IR camera. In this study, an optimized Neural Learning based Blind Source Separation (NLBSS) algorithm, including Principal Component Analysis (PCA), and Independent Component Analysis (ICA) is demonstrated to automatically extract principal temporal and spatial features of thermography frames to enhance flaw detection. By using the NLBSS algorithm, material internal defects can be automatically detected. Furthermore, this processing approach compensates for experimental thermal imaging artifacts, such as noise and uneven heating. By merging artificial intelligence with phtotothermics, the NDE system detects internal calibrated defects of various sizes and depths in AM nuclear-grade metallic alloys.

36 MATERIALS SCIENCE↗

Three beam-combining schemes in a color projection display

Several beam-combining schemes for on-axis and off-axis optical system layout are presented. The on-axis approaches include two crossed plates with dichroic coatings placed at 90 deg, with respect to each other, and a pentaprism arrangement. The off-axis layout of the cathode ray tubes requires that the images be combined at the display screen. These image-combining approaches are compared for the standard television rates of 525 lines and the high-resolution television at 1200/2000 lines under development in Japan. It is concluded that, for the high-performance, high-color fidelity, and high-resolution projection systems, which are expected to fit into a small volume of space such as a Space Station display or a cockpit panoramic display, a folded configuration with either crossed plates or pentaprism plates will result in an optimum color display.

Scholl, Marija S.↗

Exploration of Water Jets in Supersonic Crossflow Using X-Ray Diagnostics

Here, near-field structures of pure- and aerated-liquid jets injected into Mach 2 crossflow environments were experimentally investigated at the 7-BM beamline of the Advanced Photon Source at Argonne National Laboratory using high-speed shadowgraph imaging, high-speed x-ray imaging, and pathlength-integrated x-ray fluorescence. Liquid was flush injected into a blowdown supersonic wind tunnel. Test section top and side windows were fitted with a polycarbonate plate for high x-ray transmittance. An axisymmetric aerated-liquid injector was fitted with an exchangeable nozzle adaptor to generate a liquid jet. Water and nitrogen, the gas used for aerated-liquid jets, were doped with specially selected dopants to facilitate x-ray measurements. Liquid column structures for a pure-liquid jet, typically masked by dense droplet clouds in a supersonic crossflow environment, were visualized with the present x-ray imaging setup. Surface-wave formation, movement, and transformation on the column windward surface of the pure-liquid jet, along with column deformation and breakup processes, were qualitatively characterized. We measured time-averaged line-of-sight (LOS) liquid mass distributions within the liquid jet near fields. Cross-sectional liquid column contours of pure-liquid jets at various deformation stages were reconstructed from LOS liquid mass distributions. The pure-liquid jet deformed liquid column reached a maximum width of 1.47 times the orifice diameter before exhibiting rapid mass removal. We also observed the plume-crossing phenomenon in the aerated-liquid jet.

47 OTHER INSTRUMENTATION↗

Onset dynamics of air-water menisci on rock fracture surfaces

Information on menisci dynamics and equilibrium contact angles, θ e , is needed for modeling multiphase flow of fluids in geologic formations. The wettability of fracture faces is relevant to applications such as waterflooding in enhanced oil recovery and evaluation of caprock integrity for geologic carbon sequestration. We investigated the vertical capillary rise of air-water menisci on exposed fracture faces for a sandstone, a shale, and three granites. The experimental design approximated that employed in the Wilhelmy plate method. Replicate fracture faces were prepared by fracturing cylindrical rock cores using the Brazilian method and splitting the fractured cores apart along their fracture planes. Meniscus onset was imaged from a cross-sectional perspective using dynamic neutron radiography, and quantified with change point analysis. An existing model for meniscus onset fitted the experimental data very well (median R 2 = 0.96). Capillary rise was typified by t 2/3 scaling (where t is time), followed by a constant equilibrium height, z e . The average time taken for the menisci to reach z e was 0.39 s, with no differences between rock types. The menisci achieved a greater vertical extent on the fracture faces of the sedimentary rocks as compared to those of the granites. Apparent θ e values were calculated from the best fit estimates of z e using the Wilhelmy plate equation for a smooth and planar vertical surface. Despite the fractal roughness of some of the fracture faces, there was a significant linear relationship (R 2 = 0.80) between the apparent θ e values and intrinsic θ e values measured on polished surfaces of the same rocks using the sessile drop method. The regression equation indicated the apparent θ e values were consistently greater than the intrinsic values. This overestimation may be due to averaging of pixels at the air-water-solid interface, a required step in the image analysis. Further exploration of the range of applicability and measurement accuracy of this proposed new technique would be valuable.

58 GEOSCIENCES↗

In Situ Li Seed Formation Enables Uniform Plating in Anode-Free Solid-State Batteries

Anode-free solid-state batteries (AFSSBs) are a promising route toward achieving high energy density. In these cells, the anode contains no pre-stored lithium (Li). Instead, all Li inventory originates from the cathode and is freshly deposited onto a bare current collector during charging. However, achieving uniform and defect-free Li plating on this bare current collector remains a major challenging, often resulting in low Li plating/stripping efficiency and rapid capacity decay. Here, for the first time, operando neutron imaging is employed to visualize Li plating/stripping behavior in an anode-free full cell with LiNi 0.82 Mn 0.07 Co 0.11 O 2 (NMC) as the cathode. Operando measurements reveal that complete stripping of Li leaves isolated Li residues on the current collector, which degrades interfacial contact between the current collector and solid-state electrolyte. To mitigate this interfacial issue and promote more uniform Li deposition, we implement a discharge cutoff voltage strategy that intentionally retains a thin residual Li layer after stripping. This thin Li layer, serving as an in situ–formed seed layer, not only enables more homogeneous subsequent Li plating but also improves interfacial contact. As a result, the anode-free cell with a controlled discharge voltage of 3.5 V exhibits excellent long-term cycling stability, maintaining a discharge capacity of 116 mAh g -1 with a retention rate of 83.4% and an average Coulombic efficiency of approximately 99.9% after 430 cycles at 0.25 C. In contrast, the cell with a conventional discharge cutoff voltage of 2.8 V exhibits rapid capacity decay, retaining only 59.7 mAh g -1 after 50 cycles with a capacity retention of 40.7%. This work offers a practical strategy to unlock the long-term viability of anode-free solid-state batteries.

25 ENERGY STORAGE↗

Web Exploration Tools for a Fast Federated Optical Survey Database

We implemented several new web-based tools to improve the efficiency and versatility of access to the APS Catalog of the POSS I (Palomar Observatory-National Geographic Sky Survey) and its associated image database. The most important addition was a federated database system to link the APS Catalog and image database into one Internet-accessible database. With the FDBS, the queries and transactions on the integrated database are performed as if it were a single database. We installed Myriad the FDBS developed by Professor Jaideep Srivastava and members of his group in the University of Minnesota Computer Science Department. It is the first system to provide schema integration, query processing and optimization, and transaction management capabilities in a single framework. The attached figure illustrates the Myriad architecture. The FDBS permits horizontal access to the data, not just vertical. For example, for the APS, queries can be made not only by sky position, but also by any parameter present in either of the databases. APS users will be able to produce an image of all the blue galaxies and stellar sources for comparison with x-ray source error ellipses from AXAF (X Ray Astrophysics Facility) (Chandra) for example. The FDBS is now available as a beta release with the appropriate query forms at our web site. While much of our time was occupied with adapting Myriad to the APS environment, we also made major changes in Star Base, our DBMS for the Catalog, at the web interface to improve its efficiency for issuing and processing queries. Star Base is now three times faster for large queries. Improvements were also made at the web end of the image database for faster access; although work still needs to be done to the image database itself for more efficient return with the FDBS. During the past few years, we made several improvements to the database pipeline that creates the individual plate databases queries by StarBase. The changes include improved positions especially for galaxies, using a new median centroider and integrated magnitudes for galaxies with an improved density-to-intensity calibration with a "sky" background subtraction. In the original version of StarBase the object classification fainter than 19.5-20.0 mag., was an extrapolation of the networks trained on brighter objects. We have used a new catalog of galaxies at the NGP to train a neural network on objects fainter than 20th mag. This improved classification is used in the new version of StarBase. We have also added a FITS table option for the returned data from queries on the object catalog. The APS image database includes images in both colors so we have added a tool for querying the image database in both colors simultaneously. The images can be displayed in parallel or blinked for comparison.

Humphreys, Roberta M.↗

Effects of shielding gas and spot reduction on humping suppression in high-speed laser welding

High-speed laser welding is a crucial process to enhance the production rate of fuel cell fabrication. However, exceeding a critical welding speed leads to defect formation such as humps and root concavities, which degrade weld quality and mechanical performance. This study employed shielding gas and spot reduction approaches to suppress these defects. The relationships between individual defect types and their influence on weld strength were systematically examined. Moreover, in situ high-speed synchrotron X-ray imaging was employed to comprehend the mechanisms of humping mitigation by shielding gas through analysis of instantaneous keyhole and melt pool dynamics. The observations reveal that shielding gas mitigates humping by shortening the molten pool through enhanced surface heat convection and by altering surface tension to prevent melt flow collisions. The effects of shielding gas and spot reduction were further incorporated into the dimensionless humping index (π h ) that describes the humping formation tendency. These findings provide mechanistic insights and quantitative guidance for defect control strategies in high-speed laser welding.

08 HYDROGEN↗

Characterization and Simulation of Optical Delay System for the Proof-of-Principle Experiment of Optical Stochastic Cooling at IOTA

The Optical Stochastic Cooling (OSC) experiment at Fermilab’s IOTA storage ring uses two undulators to cool the beam over many turns. The radiation emitted by electrons in the first undulator is delayed and imaged in the second undulator where it applies a corrective energy kick on the electrons. Imperfections in the manufacturing of the delay plates can lead to a source of error. This paper presents the experimental characterization of the absolute thickness of these delay plates using an interferometric technique. The measured "thickness maps" are implemented in the Synchrotron Radiation Workshop (SRW) program to assess their impact on the delayed radiation pulse.

43 PARTICLE ACCELERATORS↗

Photon-counting detector arrays based on microchannel array plates

The recent development of the channel electron multiplier (CEM) and its miniaturization into the microchannel array plate (MCP) offers the possibility of fully combining the advantages of the photographic and photoelectric detection systems. The MCP has an image-intensifying capability and the potential of being developed to yield signal outputs superior to those of conventional photomultipliers. In particular, the MCP has a photon-counting capability with a negligible dark-count rate. Furthermore, the MCP can operate stably and efficiently at extreme-ultraviolet and soft X-ray wavelengths in a windowless configuration or can be integrated with a photo-cathode in a sealed tube for use at ultraviolet and visible wavelengths. The operation of one- and two-dimensional photon-counting detector arrays based on the MCP at extreme-ultraviolet wavelengths is described, and the design of sealed arrays for use at ultraviolet and visible wavelengths is briefly discussed.

Timothy, J. G.↗

Fast Laser Holographic Interferometry For Wind Tunnels

Proposed system makes holographic interferograms quickly in wind tunnels. Holograms reveal two-dimensional flows around airfoils and provide information on distributions of pressure, structures of wake and boundary layers, and density contours of flow fields. Holograms form quickly in thermoplastic plates in wind tunnel. Plates rigid and left in place so neither vibrations nor photgraphic-development process degrades accuracy of holograms. System processes and analyzes images quickly. Semiautomatic micro-computer-based desktop image-processing unit now undergoing development moves easily to wind tunnel, and its speed and memory adequate for flows about airfoils.

Lee, George↗

Crossflow instability control on a swept-wing: Preliminary studies

The pressure distribution on a swept wing causes the streamlines at the edge of the boundary layer to be curved. This pressure gradient normal to the external streamline creates a velocity component normal to the external streamline within the boundary layer which is referred to as the crossflow velocity. Because the crossflow velocity profile perpendicular to the wing surface has an inflection point, the profile is unstable. The stationary instability mode takes the form of crossflow vortices. Under these conditions, the boundary layer on the wing is extremely unstable and transition to turbulent flow takes place much closer to the leading edge of the wing than it would on an unswept wing. Higher skin friction drag is associated with turbulent flow, and so better aircraft performance could be obtained if the crossflow could be eliminated One method of controlling crossflow that is being investigated is boundary-layer suction. An extensive airfoil suction experiment in the 8 feet Transonic Pressure Tunnel (TPT) at NASA Langley Research Center will begin late in 1994. Because of the size, complexity, and expense associated with this test, a number of 'risk-reduction' tests are currently being conducted. The 20 x 28 in. Shear Flow Control Tunnel at NASA Langley is being used for some of these tests. Prior to the summer of 1994, a flat plate with a swept leading edge was installed in the 20 x 28 in. tunnel, with a displacement body mounted on the tunnel ceiling that created a pressure distribution on the plate similar to the pressure distribution on a swept wing. The flow over the plate was investigated during the summer of 1994 using a laser Doppler velocimeter (LDV) system. The LDV measurements indicated the possible presence of multiple disturbance modes, a rarely-seen phenomena since, in most tests, one disturbance mode dominates. The possible existence of multiple disturbance modes in the flat plate boundary layer, however, means that the flow in the 20 x 28 in. tunnel is of interest itself, and will be investigated more thoroughly in the future. With a view to these investigations, the boundary layer traverse mechanism in the 20 x 28 in. tunnel was modified to improve its performance, and strain gauges were mounted on the traverse in order to monitor its deflection during a test. Other preliminary work conducted in the 20 x 28 in. tunnel included the use of an infrared camera system. Previous work with this system showed that transition indeed could be detected, but the signal produced by the crossflow vortices was too weak to be detected. It was hoped that spraying the flat plate with naphthalene would augment the heat transfer associated with the crossflow vortices so that they would show up in a IR image; however, experiments showed that this would not work. Another set of tests was conducted in the 20 x 28 in. tunnel to determine the tripping requirements for a set of airfoil-shaped struts that will be used in the 8 feet TPT experiment. Since the Reynolds number associated with these struts is small, a laminar boundary layer would separate early, causing large fluctuations in the flow field. A turbulent boundary layer would remain attached further back, but tripping from laminar to turbulent flow at low Reynolds number is very difficult. However, trip strip configurations were found that should effectively trip the boundary layer at the required conditions. Currently underway is an investigation of the data acquisition requirements for the 8 feet TPT experiment, with the purpose of the finding the minimum amount of data needed to characterize sufficiently the swept-wing boundary layer. This study is being conducted using a numerically generated data set.

Bridges, David H.↗

Curved Focal-Plane Arrays Using Back-Illuminated High-Purity Photodetectors

Curved-focal-plane arrays of back-illuminated silicon-based photodetectors are being developed. The basic idea is to improve the performance of an imaging instrument and simplify the optics needed to obtain a given level of performance by making an image sensor (e.g., a photographic film or an array of photodetectors) conform to a curved focal surface, instead of following the customary practice of designing the optics to project an image onto a flat focal surface. Eyes are natural examples of optical systems that have curved focal surfaces on which image sensors (retinas) are located. One prior approach to implementation of this concept involves the use of curved-input-surface microchannel plates as arrays of photodetectors. In comparison with microchannel plates, these curved-focal-plane arrays would weigh less, operate at much lower voltages, and consume less power. It should also be possible to fabricate the proposed devices at lower cost. It would be possible to fabricate an array of photodetectors and readout circuitry in the form of a very-large-scale integrated (VLSI) circuit on a curved focal surface, but it would be difficult and expensive to do so. In a simple and inexpensive alternate approach, a device (see figure) would have (1) a curved back surface, onto which light would be focused; and (2) a flat front surface, on which VLSI circuitry would be fabricated by techniques that are well established for flat surfaces. The device would be made from ultrapure silicon, in which it is possible to form high-resistivity, thick photodetectors that are fully depleted through their thicknesses. (As used here, "thick means having a thickness between a fraction of a millimeter and a few millimeters.) The back surface would be polished to the curvature of the focal surface of the intended application. To enable the collection of charge carriers excited by photons near the back surface or in the bulk of the device, it would be necessary to form a transparent or semitransparent back-surface electrode, possibly by delta doping. [Delta doping is so named because its density-vs.-depth characteristic is reminiscent of the Dirac function (impulse function): the dopant is concentrated in a very thin layer - nominally, a single atomic layer.]

Nikzad, Shouleh↗

Anodic Interfacial Evolution in Extremely Fast Charged Lithium-Ion Batteries

Interfacial reaction mechanisms at the anode/separator interface play a central role in the performance and safety of lithium-ion batteries during fast charging. We report a mechanistic study on the evolution and interactions of the aging mechanisms at the anode/separator interface in lithium cobalt oxide/graphite pouch cells charged with variable charging rates (1–6C) over 10 cycles. In situ electrochemical measurements, including voltage relaxation, Coulombic efficiency, and direct current internal resistance, indicated an incremental lithium loss until the C rates were ≤5C. A substantial capacity fade is observed in the first few cycles of fast charging, but the magnitude of capacity fade progressively diminishes with the number of cycles, indicating a suppression in the lithium deposition mechanism. Post-mortem film thickness, X-ray photoelectron spectroscopy (XPS), and scanning electron microscopy (SEM) analyses were performed to elucidate the evolution of electrolyte decomposition, the solid–electrolyte interface (SEI), lithium plating, and film fracture mechanisms with C rate. XPS measurements confirmed an increasing lithium concentration in an SEI film with an increase in the C rate. SEM images showed a growth of dendritic lithium on the anode surface from 1C to 3C. Precrack formation leading to an interfacial film fracture was observed at higher C rates. Furthermore, a differential analysis of the discharge capacity indicated a possible two-phase delithiation from the anode and reduced cathodic lithiation due to lithium loss at high C rates.

36 MATERIALS SCIENCE↗

Controlled lithium stripping enables a stable interface for long-cycling anode-free solid-state batteries

Anode-free solid-state batteries (AFSSBs) are a promising route toward achieving high energy density. In these cells, the anode contains no pre-stored lithium (Li). Instead, the entire Li inventory originates from the cathode and is freshly deposited onto a bare current collector during charging. However, achieving uniform and defect-free Li plating on this bare current collector remains a major challenge, often resulting in low Li plating/stripping efficiency and rapid capacity decay. Here, for the first time, operando neutron imaging is employed to visualize Li plating/stripping behavior in an anode-free full cell with LiNi0.82Mn0.07Co0.11O2 (NMC) as the cathode. Operando measurements reveal that complete stripping of Li leaves isolated Li residues on the current collector, which degrades the interfacial contact between the current collector and the solid-state electrolyte. To mitigate this interfacial issue and promote more uniform Li deposition, we implement a discharge-cutoff-voltage strategy that intentionally retains a thin residual Li layer after stripping. This preserved Li-containing interfacial reservoir not only improves interfacial contact but also serves as an in situ formed seed layer that enables more homogeneous subsequent Li plating. As a result, the optimized anode-free cell with limited stripping depth exhibits excellent long-term cycling stability, maintaining a discharge capacity of 112.1 mAh g−1 with a capacity retention of 80.6% and an average coulombic efficiency of approximately 99.9% after 500 cycles at 0.25 C. In contrast, the cell with a conventional discharge cutoff voltage of 2.8 V exhibits rapid capacity decay, retaining only 59.7 mAh g−1 after 50 cycles with a capacity retention of 40.7%. This work demonstrates that limiting deep stripping to preserve a thin Li-containing interfacial layer can effectively improve the cycling stability of sulfide-based AFSSBs.

Wang, Jiwei [Northeastern University, Boston]↗

3-dimensional x-ray imager

The invention utilizes one exposure without moving parts to provide multiple x-ray views of an object. It relies on a 3D detector, which can be a stack of film plates, and a specified focusing x-ray optic. The x-ray optic, discussed below, allows collection of x-rays from a localized volume, just like an ordinary optical lens, and the stacked film plate, or other 3D detector design, allows collection of the multiple focal plane information from one line of sight.

36 MATERIALS SCIENCE↗

Comprehensive single-shot biophysical cytometry using simultaneous quantitative phase imaging and Brillouin spectroscopy

Abstract Single-cell analysis, or cytometry, is a ubiquitous tool in the biomedical sciences. Whereas most cytometers use fluorescent probes to ascertain the presence or absence of targeted molecules, biophysical parameters such as the cell density, refractive index, and viscosity are difficult to obtain. In this work, we combine two complementary techniques—quantitative phase imaging and Brillouin spectroscopy—into a label-free image cytometry platform capable of measuring more than a dozen biophysical properties of individual cells simultaneously. Using a geometric simplification linked to freshly plated cells, we can acquire the cellular diameter, volume, refractive index, mass density, non-aqueous mass, fluid volume, dry volume, the fractional water content of cells, both by mass and by volume, the Brillouin shift, Brillouin linewidth, longitudinal modulus, longitudinal viscosity, the loss modulus, and the loss tangent, all from a single acquisition, and with no assumptions of underlying parameters. Our methods are validated across three cell populations, including a control population of CHO-K1 cells, cells exposed to tubulin-disrupting nocodazole, and cells under hypoosmotic shock. Our system will unlock new avenues of research in biophysics, cell biology, and medicine.

Steelman, Zachary A.↗

General Applications for Hamilton Vantage (GenApps for Vantage) v0.6.1

General applications for Hamilton Vantage is a flexible liquid handling method used to automate the most widely applicable types of automated liquid transfers. General applications can also be used as a tool to onboard new fully-automated workflows by breaking them down step by step into single transfers. The goal of General Applications is to make using the Hamilton Vantage liquid handler as easy & practical as using a handheld pipette for the end user. The software supports plate-to-plate transfers for a variety of method types including: Stamp: One-to-One, Stamp: One-To-Many, Split, Combine, Hitpick, and Qtray plating. General Applications eliminates the need for automation engineers to customize individual methods for each new workflow that gets onboarded. Steps can be customized within GenApps according to the needs of the researcher. The software utilizes a GUI to prompt the users to input variables – Allowing for flexible control over plate types, transfer volumes, number of replicates, tip types, liquid classes, mixing steps, aspiration/dispense heights and more. General Applications also generates a deck image and setup instructions to guide the researcher on how to load the deck and start the instrument.

Yoder, Sam↗

Total reduction of distorted echelle spectrograms - An automatic procedure

A total reduction procedure, notable for its use of a computer-controlled microdensitometer for semi-automatically tracing curved spectra, is applied to distorted high-dispersion echelle spectra recorded by an image tube. Microdensitometer specifications are presented and the FORTRAN, TRACEN and SPOTS programs are outlined. The intensity spectrum of the photographic or electrographic plate is plotted on a graphic display. The time requirements are discussed in detail.

Peterson, R. C.↗