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All sources NASA NTRS DOE OSTI

DOE OSTI2021

Performance Evaluation of Comparative Vacuum Monitoring and Piezoelectric Sensors for Structural Health Monitoring of Rotorcraft Components

The costs associated with the increasing maintenance and surveillance needs of aging structures are rising at an unexpected rate. Multi-site fatigue damage, hidden cracks in hard-to-reach locations, disbonded joints, erosion, impact, and corrosion are among the major flaws encountered in today’s extensive fleet of aging aircraft and space vehicles. Aircraft maintenance and repairs represent about a quarter of a commercial fleet’s operating costs. The application of Structural Health Monitoring (SHM) systems using distributed sensor networks can reduce these costs by facilitating rapid and global assessments of structural integrity. The use of in-situ sensors for real-time health monitoring can overcome inspection impediments stemming from accessibility limitations, complex geometries, and the location and depth of hidden damage. Reliable, structural health monitoring systems can automatically process data, assess structural condition, and signal the need for human intervention. The ease of monitoring an entire on-board network of distributed sensors means that structural health assessments can occur more often, allowing operators to be even more vigilant with respect to flaw onset. SHM systems also allow for condition-based maintenance practices to be substituted for the current time-based or cycle-based maintenance approach thus optimizing maintenance labor. The Federal Aviation Administration has conducted a series of SHM validation and certification programs intended to comprehensively support the evolution and adoption of SHM practices into routine aircraft maintenance practices. This report presents one of those programs involving a Sandia Labs-aviation industry effort to move SHM into routine use for aircraft maintenance. The Airworthiness Assurance NDI Validation Center (AANC) at Sandia Labs, in conjunction with Sikorsky, Structural Monitoring Systems Ltd., Anodyne Electronics Manufacturing Corp., Acellent Technologies Inc., and the Federal Aviation Administration (FAA) carried out a trial validation and certification program to evaluate Comparative Vacuum Monitoring (CVM) and Piezoelectric Transducers (PZT) as a structural health monitoring solution to specific rotorcraft applications. Validation tasks were designed to address the SHM equipment, the health monitoring task, the resolution required, the sensor interrogation procedures, the conditions under which the monitoring will occur, the potential inspector population, adoption of CVM and PZT systems into rotorcraft maintenance programs and the document revisions necessary to allow for their routine use as an alternate means of performing periodic structural inspections. This program addressed formal SHM technology validation and certification issues so that the full spectrum of concerns, including design, deployment, performance and certification were appropriately considered. Sandia Labs designed, implemented, and analyzed the results from a focused and statistically relevant experimental effort to quantify the reliability of a CVM system applied to Sikorsky S-92 fuselage frame application and a PZT system applied to an S-92 main gearbox mount beam application. The applications included both local and global damage detection assessments. All factors that affect SHM sensitivity were included in this program: flaw size, shape, orientation and location relative to the sensors, as well as operational and environmental variables. Statistical methods were applied to performance data to derive Probability of Detection (POD) values for SHM sensors in a manner that agrees with current nondestructive inspection (NDI) validation requirements and is acceptable to both the aviation industry and regulatory bodies. The validation work completed in this program demonstrated the ability of both CVM and PZT SHM systems to detect cracks in rotorcraft components. It proved the ability to use final system response parameters to provide a Green Light/Red Light (“GO” – “NO GO”) decision on the presence of damage. In additional to quantifying the performance of each SHM system for the trial applications on the S-92 platform, this study also identified specific methods that can be used to optimize damage detection, guidance on deployment scenarios that can affect performance and considerations that must be made to properly apply CVM and PZT sensors. These results support the main goal of safely integrating SHM sensors into rotorcraft maintenance programs. Additional benefits from deploying rotorcraft Health and Usage Monitoring Systems (HUMS) may be realized when structural assessment data, collected by an SHM system, is also used to detect structural damage to compliment the operational environment monitoring. The use of in-situ sensors for health monitoring of rotorcraft structures can be a viable option for both flaw detection and maintenance planning activities. This formal SHM validation will allow aircraft manufacturers and airlines to confidently make informed decisions about the proper utilization of CVM and PZT technology. It will also streamline future regulatory actions and formal certification measures needed to assure the safe application of SHM solutions.

42 ENGINEERING↗

NASA NTRS1991

Supervised autonomous rendezvous and docking system technology evaluation

Technology for manned space flight is mature and has an extensive history of the use of man-in-the-loop rendezvous and docking, but there is no history of automated rendezvous and docking. Sensors exist that can operate in the space environment. The Shuttle radar can be used for ranges down to 30 meters, Japan and France are developing laser rangers, and considerable work is going on in the U.S. However, there is a need to validate a flight qualified sensor for the range of 30 meters to contact. The number of targets and illumination patterns should be minimized to reduce operation constraints with one or more sensors integrated into a robust system for autonomous operation. To achieve system redundancy, it is worthwhile to follow a parallel development of qualifying and extending the range of the 0-12 meter MSFC sensor and to simultaneously qualify the 0-30(+) meter JPL laser ranging system as an additional sensor with overlapping capabilities. Such an approach offers a redundant sensor suite for autonomous rendezvous and docking. The development should include the optimization of integrated sensory systems, packaging, mission envelopes, and computer image processing to mimic brain perception and real-time response. The benefits of the Global Positioning System in providing real-time positioning data of high accuracy must be incorporated into the design. The use of GPS-derived attitude data should be investigated further and validated.

Marzwell, Neville I.↗

DOE OSTI2024

Embedded High-Temperature Sensors: Enhancing Thermoelectrical Performance with Refractory Composites Gradient Layers

To monitor the stability of various energy and manufacturing systems, sensors capable of operating at temperatures exceeding 1000 °C in diverse environments for extended durations are essential. However, under harsh conditions, degradation of sensing materials is a concern that can be controlled by embedding the sensors into refractory oxides. Doped-LaCrO3 based composites are excellent candidates for high-temperature sensing applications due to their good thermoelectrical properties. However, chemical reactivity between the conductive phase and the refractory oxides can decrease the performance of the sensors. In this work, it was devised gradient-type protective layers safeguarding conductive phases within embedded thermocouples, which were fabricated and characterized by X-Ray Diffraction for phase development analysis, Scanning Electron Microscopy and Energy-dispersive X-ray spectroscopy for microstructure and cationic interdiffusion kinetics, long-term thermoelectric testing was completed up to 1400 °C. The enhanced performance of these novel sensors addresses a critical limitation, rendering them viable for long-term high-temperature applications.

20 FOSSIL-FUELED POWER PLANTS↗

NASA NTRS1977

Evaluation of Viking Lander barometric pressure sensor

Variable reluctance type pressure sensors were evaluated to determine their performance characteristics related to Viking Mission environment levels. Static calibrations were performed throughout the evaluation over the full range of the sensors using two point contact manometer standards. From the beginning of the evaluation to the end of the evaluation, the zero shift in the two sensors was within 0.5 percent, and the sensitivity shift was 0.05 percent. The maximum thermal zero coefficient exhibited by the sensors was 0.032 percent over the temperature range of -28.89 C to 71.11 C. The evaluation results indicated that the sensors are capable of making high accuracy pressure measurements while being exposed to the conditions mentioned.

Mitchell, M.↗

NASA NTRS1993

Fiber optic and laser sensors X; Proceedings of the Meeting, Boston, MA, Sept. 8-11, 1992

Topics addressed include acoustic and pressure sensors; fiber optic gyros; electric and magnetic field sensors; bend, strain, and temperature sensors; industrial applications of sensors; and processing techniques. Particular attention is given to fiber optic interferometric acoustic sensors for wind tunnel applications, polished coupler and resonator fabrication, second-harmonic detection for rotation sensing in fiber optic gyros, simplified control theory in closed-loop fiber optic gyroscopes, and a Fabry-Perot sensor with digital signal processing for the measurement of magnetostriction. Also discussed are a Bragg fiber laser sensor, commercialization of fiber optic strain gauge systems, thermal ignition in hazardous environments due to stray light from optical fibers, a system for absolute measurements by interferometric sensors, and high-performance interferometric demodulation techniques.

Udd, Eric↗

DOE OSTI2022

Real-Time Monitoring of Gas-Phase and Dissolved CO 2 Using a Mixed-Matrix Composite Integrated Fiber Optic Sensor for Carbon Storage Application

Novel chemical sensors that improve detection and quantification of CO 2 are critical to ensuring safe and cost-effective monitoring of carbon storage sites. Fiber optic (FO) based chemical sensor systems are promising field-deployable systems for real-time monitoring of CO 2 in geological formations for long-range distributed sensing. Here, a mixed-matrix composite integrated FO sensor system was developed with a purely optical readout that reliably operates as a detector for gas-phase and dissolved CO 2 . A mixed-matrix composite sensor coating consisting of plasmonic nanocrystals and hydrophobic zeolite embedded in a polymer matrix was integrated on the FO sensor. The mixed-matrix composite FO sensor showed excellent reversibility/stability in a high humidity environment and sensitivity to gas-phase CO 2 over a large concentration range. This remarkable sensing performance was enabled by using plasmonic nanocrystals to significantly enhance the sensitivity and a hydrophobic zeolite to effectively mitigate interference from water vapor. The sensor exhibited the ability to sense CO 2 in the presence of other geologically relevant gases, which is of importance for applications in geological formations. A prototype FO sensor configuration which possesses a robust sensing capability for monitoring dissolved CO 2 in natural water was demonstrated. Reproducibility was confirmed over many cycles, both in a laboratory setting and in the field. More importantly, we demonstrated on-line monitoring capabilities with a wireless telemetry system, which transferred the data from the field to a website. The combination of outstanding CO 2 sensing properties and facile coating processability makes this mixed-matrix composite FO sensor a good candidate suitable for practical carbon storage applications.

54 ENVIRONMENTAL SCIENCES↗

NASA NTRSDate not supplied

Overview and Performance of the LOFTID Instrumentation Suite

NASA’s Hypersonic Inflatable Aerodynamic Decelerator (HIAD) is an enabling technology that facilitates atmospheric entry of heavy payloads to planets such as Earth and Mars using a deployable aeroshell. The deployable nature of the HIAD technology allows it to overcome the size constraints imposed on current rigid aeroshell entry systems. This enables use of larger aeroshells resulting in increased entry system performance (e.g. higher payload mass and/or volume, higher landing altitude at Mars). On November 10th, 2022 the Low-Earth Orbit Flight Test of an Inflatable Decelerator (LOFTID) was launched out of Vandenberg Air Force Base as a secondary payload on an Atlas V rocket. After the primary payload was delivered to its orbit, the LOFTID reentry vehicle was inflated, positioned, and then separated to reenter Earth’s atmosphere at a velocity of 8.1km/s, ultimately splashing down safely in the Pacific Ocean. The flight successfully demonstrated a 6m diameter, 70-deg sphere-cone HIAD on a high-energy orbital reentry. This demonstration has provided invaluable fight data essential to characterize the vehicle performance and support the ongoing effort to further scale the HIAD technology to vehicles of 10m in diameter or greater. Aeroshells of this scale are applicable to near-term commercial applications and future NASA robotic and human exploration missions. LOFTID incorporated an extensive instrumentation suite totaling over 150 science measurements. This included thermocouples, total heat flux sensors, and a radiometer to characterize the aeroheating environment and aeroshell thermal response. An Inertial Measurement Unit (IMU), Global Positioning System (GPS), and flush air data system was included to allow post-flight reconstruction of the vehicle trajectory including a decoupling of the aerodynamics from the atmospheric density. Loadcells were used to measure HIAD structural response during entry, and cameras (both visual-spectrum and infrared) were mounted on the aft segment looking at the aeroshell to monitor structural deflection and surface temperature distribution. Finally, a single up-look camera was included which has provided a surprising amount of science potential from the spectacular footage. In addition to the primary instrumentation suite, a new Fiber Optic Sensing System (FOSS) was used to provide global temperature distributions as a technology demonstration. The system provided over 200 thermal measurements creating a thermal map for the backside of the nose Flexible Thermal Protection System. Another pair of FOSS cables were run along the rigid center structure and measured the temperature response to the vehicle wake environment. The LOFTID instrumentation suite leveraged Agency-wide expertise, with hardware development occurring at Ames Research Center, Langley Research Center, Marshall Space Flight Center, and Armstrong Flight Research Center. This paper will discuss the instrumentation selected for LOFTID, a summary of sensor in-flight performance, and will provide examples of data products from the post-flight analysis effort.

Gregory T Swanson↗

NASA NTRSDate not supplied

Overview and Performance of the LOFTID Instrumentation Suite

Greg Swanson↗

NASA NTRS1990

A study of the applicability of gallium arsenide and silicon carbide as aerospace sensor materials

Most of the piezoresistive sensors, to date, are made of silicon and germanium. Unfortunately, such materials are severly restricted in high temperature environments. By comparing the effects of temperature on the impurity concentrations and piezoresistive coefficients of silicon, gallium arsenide, and silicon carbide, it is being determined if gallium arsenide and silicon carbide are better suited materials for piezoresistive sensors in high temperature environments. The results show that the melting point for gallium arsenide prevents it from solely being used in high temperature situations, however, when used in the alloy Al(x)Ga(1-x)As, not only the advantage of the wider energy band gas is obtained, but also the higher desire melting temperature. Silicon carbide, with its wide energy band gap and higher melting temperature suggests promise as a high temperature piezoresistive sensor.

Hurley, John S.↗

NASA NTRS1994

QPA-CLIPS: A language and representation for process control

QPA-CLIPS is an extension of CLIPS oriented towards process control applications. Its constructs define a dependency network of process actions driven by sensor information. The language consists of three basic constructs: TASK, SENSOR, and FILTER. TASK's define the dependency network describing alternative state transitions for a process. SENSOR's and FILTER's define sensor information sources used to activate state transitions within the network. Deftemplate's define these constructs and their run-time environment is an interpreter knowledge base, performing pattern matching on sensor information and so activating TASK's in the dependency network. The pattern matching technique is based on the repeatable occurrence of a sensor data pattern. QPA-CIPS has been successfully tested on a SPARCStation providing supervisory control to an Allen-Bradley PLC 5 controller driving molding equipment.

Freund, Thomas G.↗

NASA NTRSDate not supplied

Radar Measurements of Orbital Debris from the Haystack Ultra-wideband Satellite Imaging Radar (HUSIR): 2020 to 2022

For over three decades, the NASA Orbital Debris Program Office (ODPO) has partnered with the U.S. Department of Defense and the Massachusetts Institute of Technology’s Lincoln Laboratory (MIT/LL) to collect radar data on the orbital debris (OD) environment. These radar measurements are used to statistically measure cm and sub-cm debris in low Earth orbit (LEO) that is used to define the current debris environment, monitor how the environment evolves, and support predictions of the future debris environment. Currently, the principal ground-based radar sensor used by the ODPO is the MIT/LL Haystack Ultrawideband Satellite Imaging Radar (HUSIR). HUSIR provides data on OD down to approximately 5 mm in size at altitudes below 1000 km. This paper will deliver an overview of recent HUSIR measurements of the LEO debris environment for calendar years 2020 to 2022. Process improvements will be highlighted along with results of interest, including the effects of the 15 November 2021 Russian direct ascent anti-satellite (ASAT) test on the defunct COSMOS 1408 spacecraft.

Jessica A. Arnold↗

NASA NTRSDate not supplied

Radar Measurements of Orbital Debris from the Haystack Ultra-wideband Satellite Imaging Radar (HUSIR): 2020-2021

For over three decades, the NASA Orbital Debris Program Office (ODPO) has partnered with the U.S. Department of Defense and the Massachusetts Institute of Technology’s Lincoln Laboratory (MIT/LL) to collect radar data on the orbital debris (OD) environment. These radar measurements are used to statistically measure centimeter (cm) and sub-cm debris in low Earth orbit (LEO) that is used to define the current debris environment, monitor how the environment evolves, and support predictions of the future debris environment. Currently, the principal ground-based radar sensor used by the ODPO is the MIT/LL Haystack Ultrawideband Satellite Imaging Radar (HUSIR). HUSIR provides data on OD down to approximately 5 mm in size at altitudes below 1000 km. This paper will deliver an overview of recent HUSIR measurements of the LEO debris environment for calendar years 2020 to 2022. Process improvements will be highlighted along with results of interest, including the effects of the 15 November 2021 Russian direct ascent anti-satellite (ASAT) test on the defunct Cosmos 1408 spacecraft.

Jessica A Arnold↗

DOE OSTI2020

Non-visual analysis of miniaturized melt wire arrays for in-pile measurement of peak irradiation temperature

As a part of the in-pile instrumentation program, the Idaho National Laboratory (INL) has established in-house capabilities to fabricate and test new advanced manufactured printed sensors for measurement of peak temperature inside the harsh environment of a nuclear test reactor. Although nuclear test reactors may use standard methods that can provide real-time temperature information, such as thermocouples, the need for feedthroughs for real-time measurements greatly increases the cost of the experiment. Some experiments also present the problem of limited space available for instrumentation. To address this need, INL is working to improve temperature detection options for such applications. The lab is developing advanced manufactured melt wire arrays to determine peak temperatures in experiments with limited space. Furthermore, capabilities to print multiple melt wires with different melting properties on a single miniaturized unit is being established. Recent results and knowledge from this ongoing work have made it possible to develop unique temperature sensors that can accomplish user specific temperature ranges inside the harsh environments experienced during radiation testing.

36 MATERIALS SCIENCE↗

NASA NTRS1997

Experimental Robot Position Sensor Fault Tolerance Using Accelerometers and Joint Torque Sensors

Robot systems in critical applications, such as those in space and nuclear environments, must be able to operate during component failure to complete important tasks. One failure mode that has received little attention is the failure of joint position sensors. Current fault tolerant designs require the addition of directly redundant position sensors which can affect joint design. The proposed method uses joint torque sensors found in most existing advanced robot designs along with easily locatable, lightweight accelerometers to provide a joint position sensor fault recovery mode. This mode uses the torque sensors along with a virtual passive control law for stability and accelerometers for joint position information. Two methods for conversion from Cartesian acceleration to joint position based on robot kinematics, not integration, are presented. The fault tolerant control method was tested on several joints of a laboratory robot. The controllers performed well with noisy, biased data and a model with uncertain parameters.

Aldridge, Hal A.↗

DOE OSTI2020

Relation Inference among Sensor Time Series in Smart Buildings with Metric Learning

Smart Building Technologies hold promise for better livability for residents and lower energy footprints. Yet, the rollout of these technologies, from demand response controls to fault detection and diagnosis, significantly lags behind and is impeded by the current practice of manual identification of sensing point relationships, e.g., how equipment is connected or which sensors are co-located in the same space. This manual process is still error-prone, albeit costly and laborious.We study relation inference among sensor time series. Our key insight is that, as equipment is connected or sensors co-locate in the same physical environment, they are affected by the same real-world events, e.g., a fan turning on or a person entering the room, thus exhibiting correlated changes in their time series data. To this end, we develop a deep metric learning solution that first converts the primitive sensor time series to the frequency domain, and then optimizes a representation of sensors that encodes their relations. Built upon the learned representation, our solution pinpoints the relationships among sensors via solving a combinatorial optimization problem. Extensive experiments on real-world buildings demonstrate the effectiveness of our solution.

96 KNOWLEDGE MANAGEMENT AND PRESERVATION↗

NASA NTRS2011

Testing of a Wireless Sensor System for Instrumented Thermal Protection Systems

Funded by NASA's Constellation Universities Institutes Project (CUIP), we have been developing and testing a system to wirelessly power and collect data from sensors on space platforms in general and, in particular, the harsh environment of spacecraft re-entry. The elimination of wires and associated failures such as chafing, sparking, ageing, and connector issues can increase reliability and design flexibility while reducing costs. These factors present an appealing case for the pursuit of wireless solutions for harsh environments, particularly for their use in space and on spacecraft. We have designed and built a prototype wireless sensor system. The system, with capabilities similar to that of a wired sensor system, was tested in NASA Ames Research Center s Aerodynamic Heating Facility and Interaction Heating Facility. This paper discusses the overall development effort, testing results, as well as future directions.

Kummer, Allen T.↗

DOE OSTI2025

Virtual sensing-enabled digital twin framework for real-time monitoring of nuclear systems leveraging deep neural operators

Abstract Real-time monitoring is a foundation of nuclear digital twin technology, crucial for detecting material degradation and maintaining nuclear system integrity. Traditional physical sensor systems face limitations, particularly in measuring critical parameters in hard-to-reach or harsh environments, often resulting in incomplete data coverage. Machine learning-driven virtual sensors offer a transformative solution by complementing physical sensors in monitoring critical degradation indicators. This paper introduces the use of Deep Operator Networks (DeepONet) to predict key thermal-hydraulic parameters in the hot leg of pressurized water reactor. DeepONet acts as a virtual sensor, mapping operational inputs to spatially distributed system behaviors without requiring frequent retraining. Our results show that DeepONet achieves low mean squared and Relative L2 error, making predictions 1400 times faster than traditional CFD simulations . These characteristics enable DeepONet to function as a real-time virtual sensor, synchronizing with the physical system to track degradation conditions and provide insights within the digital twin framework for nuclear systems.

Hossain, Raisa↗

NASA NTRS2012

Whispering Gallery Mode Optomechanical Resonator

Great progress has been made in both micromechanical resonators and micro-optical resonators over the past decade, and a new field has recently emerged combining these mechanical and optical systems. In such optomechanical systems, the two resonators are strongly coupled with one influencing the other, and their interaction can yield detectable optical signals that are highly sensitive to the mechanical motion. A particularly high-Q optical system is the whispering gallery mode (WGM) resonator, which has many applications ranging from stable oscillators to inertial sensor devices. There is, however, limited coupling between the optical mode and the resonator s external environment. In order to overcome this limitation, a novel type of optomechanical sensor has been developed, offering great potential for measurements of displacement, acceleration, and mass sensitivity. The proposed hybrid device combines the advantages of all-solid optical WGM resonators with high-quality micro-machined cantilevers. For direct access to the WGM inside the resonator, the idea is to radially cut precise gaps into the perimeter, fabricating a mechanical resonator within the WGM. Also, a strategy to reduce losses has been developed with optimized design of the cantilever geometry and positions of gap surfaces.

Aveline, David C.↗