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Results for “in situ data processing”

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NASA NTRS2010

SCDU Testbed Automated In-Situ Alignment, Data Acquisition and Analysis

In the course of fulfilling its mandate, the Spectral Calibration Development Unit (SCDU) testbed for SIM-Lite produces copious amounts of raw data. To effectively spend time attempting to understand the science driving the data, the team devised computerized automations to limit the time spent bringing the testbed to a healthy state and commanding it, and instead focus on analyzing the processed results. We developed a multi-layered scripting language that emphasized the scientific experiments we conducted, which drastically shortened our experiment scripts, improved their readability, and all-but-eliminated testbed operator errors. In addition to scientific experiment functions, we also developed a set of automated alignments that bring the testbed up to a well-aligned state with little more than the push of a button. These scripts were written in the scripting language, and in Matlab via an interface library, allowing all members of the team to augment the existing scripting language with complex analysis scripts. To keep track of these results, we created an easily-parseable state log in which we logged both the state of the testbed and relevant metadata. Finally, we designed a distributed processing system that allowed us to farm lengthy analyses to a collection of client computers which reported their results in a central log. Since these logs were parseable, we wrote query scripts that gave us an effortless way to compare results collected under different conditions. This paper serves as a case-study, detailing the motivating requirements for the decisions we made and explaining the implementation process.

Automation↗

DOE OSTI2023

Layer-wise Imaging Dataset from Powder Bed Additive Manufacturing Processes for Machine Learning Applications (Peregrine v2022-10.1)

This release consists of six datasets which together include multi-modal layer-wise powder bed images from two different powder bed printing technologies. These datasets are designed primarily to facilitate the development and testing of new computer vision and machine learning based anomaly and defect detection algorithms. The authors provide both training data with corresponding ground truth pixel masks and evaluation data with corresponding baseline prediction pixel masks made by a trained neural network. The laser powder bed fusion (L-PBF) datasets are sourced from EOS M290 and AddUp FormUp 350 printers and the binder jet (BJ) dataset is sourced from an ExOne M-Flex printer. The materials represented in these datasets include 17-4 PH Stainless Steel, GammaPrint-700, Inconel 718, Maraging Steel, and H13 Steel. The sensor imaging modalities represented include visible-light (VL), temporally-integrated (i.e., long duration exposure) near-infrared (TI-NIR), and wide-band infrared (IR). To download the dataset: (1) Create a Globus account. (2) Create a Globus Endpoint on your computer. (3) Transfer the dataset from the OLCF DOI-DOWNLOADS Collection to your Collection. Common troubleshooting steps: (a) Confirm that the transfer is going from OLCF DOI-DOWNLOADS to your Collection. (b) Create an exception for Globus in your antivirus software so that it can create an Endpoint. (c) Manually create a Globus access directory (where the data will be downloaded) by going to the Preferences > Access tab.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Atmospheric Carbon and Transport – America (ACT-America) Data Sets: Description, Management, and Delivery

The ACT-America project is a NASA Earth Venture Suborbital-2 mission designed to study the transport and fluxes of greenhouse gases. The open and freely available ACT-America data sets provide airborne in situ measurements of atmospheric carbon dioxide, methane, trace gases, aerosols, clouds, and meteorological properties, airborne remote sensing measurements of aerosol backscatter, atmospheric boundary layer height and columnar content of atmospheric carbon dioxide, tower-based measurements, and modeled atmospheric mole fractions and regional carbon fluxes of greenhouse gases over the Central and Eastern United States. In this study, we conducted 121 research flights during five campaigns in four seasons during 2016–2019 over three regions of the US (Mid-Atlantic, Midwest and South) using two NASA research aircraft (B-200 and C-130). We performed three flight patterns (fair weather, frontal crossings, and OCO-2 underflights) and collected more than 1,140 h of airborne measurements via level-leg flights in the atmospheric boundary layer, lower, and upper free troposphere and vertical profiles spanning these altitudes. We also merged various airborne in situ measurements onto a common standard sampling interval, which brings coherence to the data, creates geolocated data products, and makes it much easier for the users to perform holistic analysis of the ACT-America data products. Here, we report on detailed information of data sets collected, the workflow for data sets including storage and processing of the quality controlled and quality assured harmonized observations, and their archival and formatting for users. Finally, we provide some important information on the dissemination of data products including metadata and highlights of applications of ACT-America data sets.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2021

A Survey of Thermal Sensing Application in Additive Manufacturing

Industry 4.0 represents a significant change in manufacturing with the inclusion of such technologies as additive manufacturing and data analytics. In support of these changes, infrared thermal imaging (IR) and very-near infrared (VNIR) have proven invaluable in numerous applications related to additive manufacturing. In this review, these applications will be presented as they relate to polymer and metal-based additive manufacturing processes. Applications including in-situ characterization, post-build analysis, experimental setups, modeling, and machine learning will be covered. With a general overview complete, the review will conclude with a discussion of challenges identified throughout the literature and thoughts on future trends.

Borish, Michael↗

DOE OSTI2025

Cosmological Hydrodynamics at Exascale: A Trillion-Particle Leap in Capability

Resolving the most fundamental questions in cosmology requires simulations that match the scale, fidelity, and physical complexity demanded by next-generation sky surveys. To achieve the realism needed for this critical scientific partnership, detailed gas dynamics must be treated self-consistently with gravity for end-to-end modeling of structure formation. Exascale computing enables simulations that span survey-scale volumes while incorporating key astrophysical processes that shape complex cosmic structures. We present results from CRK-HACC, a cosmological hydrodynamics code built for extreme scalability. Using separation-of-scale techniques, GPU-resident tree solvers, in situ analysis pipelines, and multi-tiered I/O, CRK-HACCexecuted Frontier-E: a four trillion particle full-sky simulation, over an order of magnitude larger than previous efforts. The run achieved 513.1 PFLOPs peak performance, processing 46.6 billion particles per second and writing more than 100 PB of data in just over one week of runtime. Frontier-E marks a significant advance in predictive modeling for next-generation cosmological science.

Frontiere, Nicholas [Argonne National Laboratory (↗

NASA NTRS2002

Meteorology, Macrophysics, Microphysics, Microwaves, and Mesoscale Modeling of Mediterranean Mountain Storms: The M8 Laboratory

Comprehensive understanding of the microphysical nature of Mediterranean storms can be accomplished by a combination of in situ meteorological data analysis and radar-passive microwave data analysis, effectively integrated with numerical modeling studies at various scales, from synoptic scale down through the mesoscale, the cloud macrophysical scale, and ultimately the cloud microphysical scale. The microphysical properties of and their controls on severe storms are intrinsically related to meteorological processes under which storms have evolved, processes which eventually select and control the dominant microphysical properties themselves. This involves intense convective development, stratiform decay, orographic lifting, and sloped frontal lifting processes, as well as the associated vertical motions and thermodynamical instabilities governing physical processes that affect details of the size distributions and fall rates of the various types of hydrometeors found within the storm environment. Insofar as hazardous Mediterranean storms, highlighted in this study by three mountain storms producing damaging floods in northern Italy between 1992 and 2000, developing a comprehensive microphysical interpretation requires an understanding of the multiple phases of storm evolution and the heterogeneous nature of precipitation fields within a storm domain. This involves convective development, stratiform transition and decay, orographic lifting, and sloped frontal lifting processes. This also involves vertical motions and thermodynamical instabilities governing physical processes that determine details of the liquid/ice water contents, size disi:ributions, and fall rates of the various modes of hydrometeors found within hazardous storm environments.

Starr, David O.↗

NASA NTRS2017

Assessment of Version 4 of the SMAP Passive Soil Moisture Standard Product

NASAs Soil Moisture Active Passive (SMAP) mission launched on January 31, 2015 into a sun-synchronous 6 am6 pm orbit with an objective to produce global mapping of high-resolution soil moisture and freeze-thaw state every 2-3 days. The SMAP radiometer began acquiring routine science data on March 31, 2015 and continues to operate nominally. SMAPs radiometer-derived standard soil moisture product (L2SMP) provides soil moisture estimates posted on a 36-km fixed Earth grid using brightness temperature observations and ancillary data. A beta quality version of L2SMP was released to the public in October, 2015, Version 3 validated L2SMP soil moisture data were released in May, 2016, and Version 4 L2SMP data were released in December, 2016. Version 4 data are processed using the same soil moisture retrieval algorithms as previous versions, but now include retrieved soil moisture from both the 6 am descending orbits and the 6 pm ascending orbits. Validation of 19 months of the standard L2SMP product was done for both AM and PM retrievals using in situ measurements from global core calval sites. Accuracy of the soil moisture retrievals averaged over the core sites showed that SMAP accuracy requirements are being met.

SMAP↗

NASA NTRS2018

The SMAP Mission Combined Active-Passive Soil Moisture Product at 9 Km and 3 Km Spatial Resolutions

The NASA Soil Moisture Active Passive (SMAP) mission was launched on January 31st, 2015. The spacecraft was to provide high-resolution (3 km and 9 km) global soil moisture estimates at regular intervals by combining for the first time L-band radiometer and radar observations. On July 7th, 2015, a component of the SMAP radar failed and the radar ceased operation. However, before this occurred the mission was able to collect and process ~2.5 months of the SMAP high-resolution active-passive soil moisture data (L2SMAP) that coincided with the Northern Hemisphere's vegetation green-up and crop growth season. In this study, we evaluate the SMAP high-resolution soil moisture product derived from several alternative algorithms against in situ data from core calibration and validation sites (CVS), and sparse networks. The baseline algorithm had the best comparison statistics against the CVS and sparse networks. The overall unbiased root-mean-square-difference is close to the 0.04 cu. m/cu. m the SMAP mission requirement. A 3 km spatial resolution soil moisture product was also examined. This product had an unbiased root-mean-square-difference of ~0.053 cu. m/cu. m. The SMAP L2SMAP product for ~2.5 months is now validated for use in geophysical applications and research and available to the public through the NASA Distributed Active Archive Center (DAAC) at the National Snow and Ice Data Center (NSIDC). The L2SMAP product is packaged with the geo-coordinates, acquisition times, and all requisite ancillary information. Although limited in duration, SMAP has clearly demonstrated the potential of using a combined L-band radar-radiometer for proving high spatial resolution and accurate global soil moisture.

high resolution soil moisture↗

NASA NTRSDate not supplied

A Combined Computational, Experimental, and Technology Development Approach to In-Space Laser Manufacturing Maturation at NASA Marshall Space Flight Center

In-space manufacturing (ISM) is emerging as a field vital to continued access and capabilities in the space environment. NASA Marshall Space Flight Center (MSFC) is advancing the frontier of in-space laser manufacturing (ISLM) techniques through work initially focused on maturing laser beam welding (LBW) and laser forming (LF) for use in space. Such techniques proffer the ability to assemble and join structures in space from sheet metal or other stock – extant satellites, in situ resource utilization of Lunar regolith, etc. – by forming to desired shapes and then joining via in-space welding (ISW). ISLM processes are useful for assembly, joining, modification, and repair of structures in free space and on the Lunar surface such as large observatories, antennas, trusses, blast/thermal/radiation shields, pressure vessels, and more. However, these techniques are not yet qualified & certified (Q&C) for regular application in space. It would be prohibitively expensive, laborious, and time-consuming to perform Q&C via traditional experimental approaches as data collection & experimentation in space is resource-intensive. As such, benchmark experiments and focused, properly instrumented technology demonstration efforts in space can collect sufficient data that – when combined with verified computational models in an integrated computational materials engineering (ICME) approach – can validate ICME tools capable of translating more readily obtained ground data to in-space, in situ, computationally informed Q&C of ISLM techniques. Several ISLM projects at MSFC are obtaining the data required to validate ICME tools through both ground and flight experiments. A parabolic flight experiment of LBW under vacuum is manifested for August 2024, including both microgravity and Lunar gravity profiles. This collaboration with the Ohio State University is investigating common aerospace alloys such as 316L stainless steel, 2219 aluminum alloy, and Ti64 titanium alloy. In situ data collection includes videography, thermography, and reference thermocouples to build a thermal model of the welds. This will elucidate the relevant physics when combined with post-flight microstructural examination and mechanical testing. MSFC is also progressing towards a suborbital flight experiment of LBW under vacuum, which could provide reams of data on ISW during sustained, high-quality reduced gravity. The effect of combined thermal (cryogenic and high-temperature) and vacuum exposure on both LBW (NASA-funded) and LF (DARPA-funded) is being investigated through ground experiments. In addition to the copious data collected during these ground experiments, ruggedization of LBW hardware will also be pursued. The datasets from these experiments will be used to validate computational models which will inform future ISLM efforts in an ICME framework. A variety of techniques across lengths scales, from CALPHAD-driven thermodynamics & kinetics to phase field modeling of solidification to kinetic Monte Carlo simulations of grain evolution at the mesoscale, will be employed to accelerate the infusion and eventual Q&C of LBW and LF for use in space. The development of data-driven surrogate models to bridge ground to flight experiments and thereby reduce the need for resource-intensive experiments in space will also be investigated. These ICME techniques, surrogate models, and datasets from ground testing can also be employed to advance manufacturing in terrestrial environments.

in-space welding↗

DOE OSTI2023

Evaluation of E3SM land model snow simulations over the western United States

Abstract. Seasonal snow has crucial impacts on climate, ecosystems, and humans, but it is vulnerable to global warming. The land component (ELM) of the Energy Exascale Earth System Model (E3SM) mechanistically simulates snow processes from accumulation, canopy interception, compaction, and snow aging to melt. Although high-quality field measurements, remote sensing snow products, and data assimilation products with high spatio-temporal resolution are available, there has been no systematic evaluation of the snow properties and phenology in ELM. This study comprehensively evaluates ELM snow simulations over the western United States at 0.125∘ resolution during 2001–2019 using the Snow Telemetry (SNOTEL) in situ networks, MODIS remote sensing products (i.e., MCD43 surface albedo product), the spatially and temporally complete (STC) snow-covered area and grain size (MODSCAG) and MODIS dust and radiative forcing in snow (MODDRFS) products (STC-MODSCAG/STC-MODDRFS), and the snow property inversion from remote sensing (SPIReS) product and two data assimilation products of snow water equivalent and snow depth – i.e., University of Arizona (UA) and SNOw Data Assimilation System (SNODAS). Overall the ELM simulations are consistent with the benchmarking datasets and reproduce the spatio-temporal patterns, interannual variability, and elevation gradients for different snow properties including snow cover fraction (fsno), surface albedo (αsur) over snow cover regions, snow water equivalent (SWE), and snow depth (Dsno). However, there are large biases of fsno with dense forest cover and αsur in the Rocky Mountains and Sierra Nevada in winter, compared to the MODIS products. There are large discrepancies of snow albedo, snow grain size, and light-absorbing particle-induced snow albedo reduction between ELM and the MODIS products, attributed to uncertainties in the aerosol forcing data, snow aging processes in ELM, and remote sensing retrievals. Against UA and SNODAS, ELM has a mean bias of −20.7 mm (−35.9 %) and −20.4 mm (−35.5 %), respectively, for spring, and −13.8 mm (−27.8 %) and −10.2 mm (−22.2 %), respectively, for winter. ELM shows a relatively high correlation with SNOTEL SWE, with mean correlation coefficients of 0.69 but negative mean biases of −122.7 mm. Compared to the snow phenology of STC-MODSCAG and SPIReS, ELM shows delayed snow accumulation onset dates by 17.3 and 12.4 d, earlier snow end dates by 35.5 and 26.8 d, and shorter snow durations by 52.9 and 39.5 d, respectively. This study underscores the need for diagnosing model biases and improving ELM representations of snow properties and snow phenology in mountainous areas for more credible simulation and future projection of mountain snowpack.

54 ENVIRONMENTAL SCIENCES↗

NASA NTRSDate not supplied

In-Situ Detection of Process-Induced Porosity During Cure of Out-of-Autoclave Composites

Composite materials offer unique benefits in aerospace applications, including high strength-to-weight ratio, and are becoming increasingly used by industry manufacturers. Current manufacturing and processing methods can lead to defects in the composites, which are identified after fabrication using inspection methods. This study utilized a high-temperature ultrasonic inspection system to detect process-induced porosity in an out-of-autoclave (OOA) composite panel during cure. In order to perform ultrasonic scans in-situ during cure, the system needed to be able to operate at oven temperatures up to 200 °C. There are no commercially available ultrasonic scanning systems that can operate continuously at these temperatures, so an enclosure was fabricated to insulate the ultrasonic system in the curing oven. The enclosure housed a MISTRAS® motorized X-Y raster scanner and contact transducer (Olympus® X2002). The Olympus® X2002 contact transducer is a continuous high-temperature delay line transducer with a center frequency of 2.25 MHz. In order to prevent the inside of the enclosure from reaching high temperatures, a sparge pipe inside the cooling enclosure was connected to a liquid nitrogen (LN2) tank outside of the oven via insulated hoses. The cooling system was automatically controlled by a temperature controller that was programmed to open a solenoid valve along the hose at 31 ℃ and close at 28 ℃ inside the cooling enclosure. When the solenoid valve was open, LN2 would flow from the LN2 tank and vaporize prior to reaching cooling enclosure. A U-shaped sparge pipe had holes drilled along its length to uniformly introduce cold nitrogen gas into the cooling enclosure. This prevented the motors from ever reaching the maximum desired operating temperature of 38 ℃. In the bottom of the enclosure, the tool plate was placed with the composite facing the outside of the enclosure, exposing it to the temperatures of the oven. The tool plate was 63.5 mm thick borosilicate glass, which was chosen for its low ultrasonic attenuation and moderate thermal conductivity. A thin layer of ultrasonic couplant was placed on the tool plate. The transducer sent and received ultrasonic waves through the tool plate into the composite. A MISTRAS® Remote UT System performed all wave generation, analog to digital conversion, and data acquisition and processing. The transducer was connected directly to the Remote UT System via a high-temperature BNC cable (CD International, RG-316). Polyimide insulated copper wire was used to connect the scanner to a 2-axis motor drive, which was connected to the Remote UT System. The motor drive and Remote UT System were located outside the industrial oven. A diagram of the ultrasonic system is shown in Figure 1. Figure 1: Diagram of ultrasonic in-situ defect detection system. In this study, a porosity gradient was introduced into the carbon fiber reinforced polymer (CFRP) composite through a misfit of the part and caul plate. A 24-ply quasi-isotropic ([0/90, ±45]12S) composite panel was laid up using Newport® AS4C-M/NB321 out-of-autoclave (OOA) plain weave (PW) prepreg (42% resin content, 195 g/m2). The first 16 plies were 203 mm × 203 mm. Ply drops were incorporated into the panel by decreasing the length of plies 17-24. The sizes of each ply are included in Table 1. All plies were centered along their length (x-axis) creating a trapezoidal type cross-section. Table 1: Ply sizes Plies Length (mm) Width (mm) 1-16 203 203 17-18 102 203 19-20 85 203 21-22 68 203 23-24 51 203 A 15-5 stainless steel caul plate (Size: 203 × 203 × 1.2 mm) was placed on the laminate. The composite and caul plate were vacuum bagged to the tool plate. Per the product datasheet, Newport 321 can be cured between 121 °C and 149 °C, depending on service temperature, with a hold for 90-120 minutes. Based on prior thermal testing of the cooling enclosure, the desired composite temperature cycle could be attained when the air temperature of the oven was ramped to 160 °C at a rate of 1.7 °C/min with a 3 hour hold. The extended hold was not necessary to cure the composite, but did allow for additional scans at the cure temperature during preliminary testing. The composite panel was under vacuum pressure for the entire cure cycle. Under vacuum, the caul plate deformed causing high and low pressure regions. The low-pressure regions formed high porosity in the composite part. The ultrasonic data collected showed that the inspection system was able to monitor the evolution of porosity within the composite throughout the cure cycle. Fifty scans of a 203 mm × 51 mm (8 in. × 2 in.) area of the composite were completed throughout the cure cycle. The scan speed was set to 43 mm/s in the x-direction and 36 mm/s in the y-direction, with a 1.0 mm/pixel resolution in both directions. Each scan took approximately five minutes to complete. Figure 2 shows C-scan amplitude data (top view) from one scan during the cure cycle. The color map indicates the maximum amplitude (%) measured with a time gate that contains reflections from the back surface (furthest from the transducer in contact with the caul plate) of the composite. Because porosity in the composite increases the ultrasonic attenuation in the composite part, a higher amplitude (red) indicates low porosity and a lower amplitude (blue) indicates high porosity. The regions where the caul plate was applying increased pressure (center and ends of the panel) resulted in reduced porosity, whereas the ply drop regions had reduced pressure and thus had higher porosity. Figure 2: Amplitude C-scan (top view) of OOA composite from one scan during the 160 °C temperature hold. Higher amplitude (red) indicates low porosity. Lower amplitude (blue) indicates high porosity. A B-scan is a two-dimensional image plotting the ultrasonic signals from a single y-position at every x-location of the composite panel. The travel time (μs) of the ultrasonic wave (representing the through-thickness location) is plotted along the y-axis, and the ultrasonic wave signal is represented as a contour map. Based on the B-scan data, the location of the defects with respect to the composite thickness was able to be determined. The ply drop regions had high porosity near the front (tool plate) surface of the composite (Figure 3). Figure 3: B-scan (cross-section view) of OOA composite from one scan during the 160 °C temperature hold. Using the data obtained from amplitude C-scans and B-scans throughout the cure cycle, the high and low porosity regions within the composite laminate were detected and localized with high spatial resolution. This paper will discuss the evolution of porosity content in the OOA composite during cure. OOA tests aided the transition of this system to an autoclave, which is the primary method of curing aerospace-grade thermoset composites.

Tyler B. Hudson↗

NASA NTRS2001

SOHO Ultraviolet Coronagraph Spectrometer (UVCS) Mission Operations and Data Analysis

The scientific goal of UVCS is to obtain detailed empirical descriptions of the extended solar corona as it evolves over the solar cycle and to use these descriptions to identify and understand the physical processes responsible for coronal heating, solar wind acceleration, coronal mass ejections (CMEs), and the phenomena that establish the plasma properties of the solar wind as measured by "in situ" solar wind instruments. This report covers the period from 15 November 1998 to 14 March 2001. During that time, UVCS observations have consisted of three types: 1) standard synoptic observations comprising, primarily, the H I Lycc line profile and the O VI 103.2 and 103.7 nm intensity over a range of heights from 1.5 to about 3.0 solar radii and covering 360 degrees about the sun, 2) sit and stare watches for CMEs, and 3) special observations designed by the UVCS Lead Observer of the Week for a specific scientific purpose. The special observations are often coordinated with those of other space-based and ground based instruments and they often are part of SOHO joint observation programs and campaigns. Lead observers have included UVCS Co-Investigators, Guest Investigators, scientists from the solar physics community and several graduate and undergraduate level students. UVCS has continued to successfully meet its goal of using powerful spectroscopic diagnostic techniques to obtain a much more detailed description of coronal structures than existed before the SOHO mission. The new descriptions of coronal structures from UVCS have inspired a large number of theoretical studies aimed at identifying the physical processes responsible for solar wind acceleration in coronal holes and streamers. UVCS has proven to be a very stable instrument. Stellar observations have demonstrated its stability and the analysis of coordinated observations with Spartan 201 have verified the accuracy of the absolute calibration and spectral resolution at H I Ly (alpha) line profile. UVCS has required no flight software modifications and all mechanisms are operational. The UVCS O VI Channel with its redundant optical path for wavelengths near H I Ly (alpha) is capable of observing the entire UVCS wavelength range. Since December 1998, the O VI Channel has been used for all UVCS observations. Although the H I Ly (alpha) Channel and detector are still operational, increases in the dark count up to about 5x 10(exp-4) counts/sec/pixel and an increase in high voltage current to within a factor of two of the maximum used in the laboratory before flight led to the decision to not use that detector at the present time. There is no significant science impact since the O VI Channel can observe nearly the same wavelength range.

Kohl, John L.↗

NASA NTRS2002

Soho Ultraviolet Coronograph Spectrometer (UVCS) Mission Operations and Data Analysis

Kohl, John L.↗

DOE OSTI2023

Application of unsupervised deep learning to image segmentation and in-situ contact angle measurements in a CO 2 -water-rock system

Rock surface wettability is a critical property that regulates multiphase flows in porous media, which can be quantified using the surface contact angle (CA). X-ray micro-computed tomography (μCT) provides an effective approach to in-situ measurements of surface CAs. However, the CA measurement accuracy depends significantly on the quality of CT image segmentation, which is the clustering of CT pixels into separate phases. Inspired by this, we developed a deep learning (DL)-based CA measurement workflow. Motivated by the recent tremendous progress in unsupervised learning techniques and aiming to avoid expensive manual data annotations, an unsupervised DL pipeline for CT image segmentation was proposed and implemented, which includes unsupervised model training and post-processing. The unsupervised model training was driven by a novel loss function constrained with feature similarity and spatial continuity and implemented by iterative forward and backward paths; the former clustered the pixel-wise feature vectors extracted by convolution neural networks, whereas the latter updated the parameters using gradient descent. An over-segmentation strategy was adopted for model training. The post-processing steps based on agglomerative hierarchical clustering (AHC) were implemented to further merge the over-segmented model output to the desired cluster number, which is intended to improve the efficiency of image segmentation. The developed unsupervised DL pipeline was compared with other commonly-used image segmentation methods using pixel-wise and physics-based evaluation metrics on a synthetic raw-image dataset, which had a known ground truth. The unsupervised DL pipeline showed the best performance. Next, the segmented images were input to an automatic CA measurement tool, and the results were validated by comparisons with manual measurements. The CA values from the manual and automatic measurements showed similar distributions and statistical properties. The automatic measurement demonstrated a wider spectrum because of the much larger number of measurement data points. The primary novelty of the unsupervised DL pipeline developed in this study lies in the novel loss function and the over-segmentation strategy associated with AHC post-processing. Finally, the workflow has been proven an efficient tool for pore-scale wettability characterization, which has a wide range of applications in fundamental studies of multiphase flows in natural porous media, which have critical implications to geological carbon sequestration, hydrocarbon energy recovery, and contaminant transport in groundwater.

42 ENGINEERING↗

DOE OSTI2022

In-process monitoring and prediction of droplet quality in droplet-on-demand liquid metal jetting additive manufacturing using machine learning

Abstract In droplet-on-demand liquid metal jetting (DoD-LMJ) additive manufacturing, complex physical interactions govern the droplet characteristics, such as size, velocity, and shape. These droplet characteristics, in turn, determine the functional quality of the printed parts. Hence, to ensure repeatable and reliable part quality it is necessary to monitor and control the droplet characteristics. Existing approaches for in-situ monitoring of droplet behavior in DoD-LMJ rely on high-speed imaging sensors. The resulting high volume of droplet images acquired is computationally demanding to analyze and hinders real-time control of the process. To overcome this challenge, the objective of this work is to use time series data acquired from an in-process millimeter-wave sensor for predicting the size, velocity, and shape characteristics of droplets in DoD-LMJ process. As opposed to high-speed imaging, this sensor produces data-efficient time series signatures that allows rapid, real-time process monitoring. We devise machine learning models that use the millimeter-wave sensor data to predict the droplet characteristics. Specifically, we developed multilayer perceptron-based non-linear autoregressive models to predict the size and velocity of droplets. Likewise, a supervised machine learning model was trained to classify the droplet shape using the frequency spectrum information contained in the millimeter-wave sensor signatures. High-speed imaging data served as ground truth for model training and validation. These models captured the droplet characteristics with a statistical fidelity exceeding 90%, and vastly outperformed conventional statistical modeling approaches. Thus, this work achieves a practically viable sensing approach for real-time quality monitoring of the DoD-LMJ process, in lieu of the existing data-intensive image-based techniques.

Gaikwad, Aniruddha (ORCID:0000000285642621)↗

DOE OSTI2023

High-throughput Li plating quantification for fast-charging battery design

Fast charging of most commercial lithium-ion batteries is limited due to fear of lithium plating on the graphite anode, which is difficult to detect and poses considerable safety risk. In this report we demonstrate the power of simple, accessible and high-throughput cycling techniques to quantify irreversible Li plating spanning data from over 200 cells. We first observe the effects of energy density, charge rate, temperature and state of charge on lithium plating, use the results to refine a mature physics-based electrochemical model and provide an interpretable empirical equation for predicting the plating onset state of charge. We then explore the reversibility of lithium plating and its connection to electrolyte design for preventing irreversible Li accumulation. Finally, we design a method to quantify in situ Li plating for commercially relevant graphite|LiNi 0.5 Mn 0.3 Co 0.2 O 2 (NMC) cells and compare with results from the experimentally convenient Li|graphite configuration. The hypotheses and abundant data herein were generated primarily with equipment universal to the battery researcher, encouraging further development of innovative testing methods and data processing that enable rapid battery engineering.

25 ENERGY STORAGE↗

DOE OSTI2023

The kinetics of the PuO 2 to Pu 2 O 3 conversion

Here in an oxidizing environment, the oxide formed on plutonium (Pu) metal is composed of a plutonium dioxide (PuO 2 ) top layer and a thin cubic plutonium sesquioxide (Pu 2 O 3 ) middle layer. In a reducing environment, the PuO 2 layer auto-reduces to cubic Pu 2 O 3 . The speed and extent of this conversion depend on the combination of temperature and time. While PuO 2 provides a strong diffusion barrier against unwanted Pu corrosion by gaseous species (like hydrogen), Pu 2 O 3 does not, since its crystal structure has chains of oxygen vacancies. The kinetics of the PuO 2 reduction are, therefore, of fundamental interest and enable researchers to better protect Pu from corrosion. In this report, the oxygen-diffusion-limited kinetics of the dioxide to sesquioxide conversion were obtained by dynamically heating a PuO 2 -covered Pu sample from 294 to 418 K in a high-vacuum vessel equipped with an in situ spectroscopic ellipsometer. The physical/chemical constraints in the conversion process were combined with the ellipsometry method of multi-sample analysis to track the percentage of PuO 2 and to compute the extent of Pu 2 O 3 formation. The resulting diffusion coefficients were compared against and then combined with complementary literature data to produce a comprehensive set of kinetic parameters for reliably modeling oxide conversion over a larger temperature range than spanned by prior studies. The extracted thermal activation energy barrier (43.7 kJ/mol) and pre-exponential factor (5.0 × 10 -10 cm 2 /s) for the oxygen-diffusion-limited process can be used to accurately model the PuO 2 to Pu 2 O 3 transformation in vacuum and/or inert gas applications.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Real-time streaming tomographic reconstruction with on-demand data capturing and 3D zooming to regions of interest

Complex dynamic tomographic experiments at brilliant X-ray light sources require real-time feedback on the sample changes with respect to environmental conditions, selecting representative regions of interest for high-resolution scanning, and on-demand data saving mechanisms for storing only relevant projections acquired by fast area detectors and reducing data volumes. Here the implementation details of a 3D real-time imaging monitoring instrument, with zooming to a volume of interest with easy-to-use visualization via ImageJ , a tool familiar to most beamline users, is presented. The instrument relies on optimized data flow between the detector and processing machines and is implemented on commodity computers. The instrument has been developed at beamline 2-BM of the Advanced Photon Source, where the automatic lens changing mechanism for zooming is implemented with an Optique Peter microscope. Performance tests demonstrate the ability to process more than 3 GB of projection data per second and generate real-time 3D zooming with different magnification. These new capabilities are essential for new APS Upgrade instruments such as the projection microscope under development at beamline 32-ID. The efficacy of the proposed instrument was demonstrated during an in situ tomographic experiment on ice and gas hydrate formation in porous samples.

3D zooming↗