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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Effect of Loading Frequency on Fatigue Behavior of Additively Manufactured Short Fiber Thermoplastics via Infrared Thermography

Fracture, Fatigue, Failure, Damage Evolution and Thermomechanics & Infrared Imaging, Volume 4 of the Proceedings of the 2025 SEM Annual Conference & Exposition on Experimental and Applied Mechanics, the fourth volume of five from the Conference, brings together contributions to this important area of research and engineering. The collection presents early findings and case studies on a wide range of areas, including: • 3D Deformation and Failure • In-situ Techniques and Microscale Effects on Mechanical Behavior • Vibration and Cyclic Fatigue • Integration of Models and Experiments • Interface-Mediated Damage and Failure • Fracture and Fatigue in Brittle Materials • Material Characterizations Using Thermography • Fatigue, Damage & Fracture Evaluation Using Infrared Thermography

Pathak, Pharindra [Auburn University]↗
DOE OSTI2022

Smart detection of indoor occupant thermal state via infrared thermography, computer vision, and machine learning

The ability to measure occupants’ thermal state in real time will enable major advances in the control of air conditioning systems. This study proposes predicting occupant thermal state by a combination of infrared thermography, computer vision, and machine learning. The approach (1) uses cheek, nose, and hand temperatures because they are least subject to blockage by hair, glasses, and clothing; (2) measures the distribution of skin temperatures within geometrically defined sub-areas of the face and hand; and (3) uses temperature differences within and between these areas to eliminate the effects of calibration drift that are unavoidable in thermal infrared (TIR) cameras. Two series of tests were conducted, respectively in an outdoor carport and an indoor environmental chamber, collecting a total of 48,422 sets of cheek, nose, and hand skin temperatures using a TIR camera and computer-vision technology, coupled with 715 subjective responses of thermal sensations. To predict occupant thermal state, Random Forest classification models were built using either absolute skin temperatures (the maximum and median temperatures of cheek and hand segments, and the temperature of the central spot on the nose), or intra- and inter-segment temperature differences of cheeks, hands, and nose. These measurements were found to accurately predict occupant thermal state. Using the maximum and median temperatures for cheek and nose, or for cheek and hand, predicts thermal state with an accuracy of 92–96%. In conclusion, using only the intra- and inter-segment temperature differences from cheek and nose is 83% accurate; adding the hand temperature differences increases the accuracy to 96%.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2016

Defect Detection in Fuel Cell Gas Diffusion Electrodes Using Infrared Thermography

Polymer electrolyte membrane fuel cells are energy conversion devices that offer high power densities and high efficiencies for mobile and other applications. Successful introduction into the marketplace requires addressing cost barriers such as production volumes and platinum loading. For cost reduction, it is vital to minimize waste and maximize quality during the manufacturing of platinum-containing electrodes, including gas diffusion electrodes (GDEs). In this work, we report on developing a quality control diagnostic for GDEs, involving creating an ex situ exothermic reaction on the electrode surface and using infrared thermography to measure the resulting temperature profile. Experiments with a moving GDE containing created defects were conducted to demonstrate the applicability of the diagnostic for real-time web-line inspection.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2024

Examining infrared thermography based approaches to rapid fatigue characterization of additively manufactured compression molded short fiber thermoplastic composites

A novel additive manufacturing (AM) methodology combined with a compression molding (CM) process has been developed to optimize the microstructure of short fiber thermoplastic composites (SFTs)with higher fiber alignment and lower porosity, yielding superior stiffness, strength, and structural integrity. Here, the current work examines the efficacy of the ‘passive’ infrared thermography (IRT) techniques for rapid fatigue characterization of SFTs that use the surface temperature evolution during cyclic loading due to self-heating as a fatigue indicator. A comparison of fatigue limits obtained from traditional stress-life (SN) (≈53.1%σ uts ) and IRT (≈54.1%σ uts ) shows a close match. However, the SN curve required 18 specimens and two weeks of continuous cyclic testing, while IRT used three specimens with 5 hours of testing. Thus, the IRT approach provides an accelerated testing framework for rapidly estimating the fatigue limit. Additionally, existing phenomenological approaches to IRT fatigue characterization have been examined.

42 ENGINEERING↗
DOE OSTI2018

Impacts of electrode coating irregularities on polymer electrolyte membrane fuel cell lifetime using quasi in-situ infrared thermography and accelerated stress testing

In-line quality control diagnostics for roll-to-roll (R2R) manufacturing techniques will play a key role in the future commercialization of the polymer electrolyte membrane fuel cell (PEMFC) used in automotive applications. These diagnostics monitor the fabrication of the membrane electrode assembly (MEA), which detect and flag any non-uniformity that may potentially harm PEMFC performance and/or lifetime. This will require quantitative thresholds and a clear distinction between harmful defects and harmless coating irregularities. Thus, novel fuel cell hardware with quasi in-situ infrared (IR) thermography capabilities is utilized to understand how bare spots in the cathode electrode impact MEA lifetime. An accelerated stress test (AST) simulates chemical and mechanical degradation modes seen in vehicular operation. The actual open circuit voltage and rate of change of this voltage are used as in-situ indicators for MEA failure, enabling capture of the progression of failure point development. Bare spot coating irregularities located at the center of the electrode were found to have no impact on MEA lifetime when compared to a pristine MEA. However, MEA lifetime was found to be considerably shortened when these same irregularities are located at the cathode inlet and, especially, the anode inlet regions of the fuel cell.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Probing temperature gradients within the GaN buffer layer of AlGaN/GaN high electron mobility transistors with Raman thermography

We demonstrate the ability of confocal Raman thermography using a spatial filter and azimuthal polarization to probe vertical temperature gradients within the GaN buffer layer of operating AlGaN/GaN high electron mobility transistors. Temperature gradients in the GaN layer are measured by using offset focal planes to minimize the contribution from different regions of the GaN buffer. The measured temperature gradient is in good agreement with a thermal simulation treating the GaN thermal conductivity as homogeneous throughout the layer and including a low thermal conductivity nucleation layer to model the heat flow between the buffer and substrate.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2014

The development of in-situ calibration method for divertor IR thermography in ITER

For the development of the calibration method of the emissivity in IR light on the divertor plate in ITER divertor IR thermography system, the laboratory experiments have been performed by using IR instruments. The calibration of the IR camera was performed by the plane black body in the temperature of 100–600 degC. The radiances of the tungsten heated by 280 degC were measured by the IR camera without filter (2.5–5.1 μm) and with filter (2.95 μm, 4.67 μm). The preliminary data of the scattered light of the laser of 3.34 μm that injected into the tungsten were acquired.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2015

Real time capable infrared thermography for ASDEX Upgrade

Infrared (IR) thermography is widely used in fusion research to study power exhaust and incident heat load onto the plasma facing components. Due to the short pulse duration of today’s fusion experiments, IR systems have mostly been designed for off-line data analysis. For future long pulse devices (e.g., Wendelstein 7-X, ITER), a real time evaluation of the target temperature and heat flux is mandatory. This paper shows the development of a real time capable IR system for ASDEX Upgrade. A compact IR camera has been designed incorporating the necessary magnetic and electric shielding for the detector, cooler assembly. The camera communication is based on the Camera Link industry standard. The data acquisition hardware is based on National Instruments hardware, consisting of a PXIe chassis inside and a fibre optical connected industry computer outside the torus hall. Image processing and data evaluation are performed using real time LabVIEW.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2020

Dark Lock-in Thermography Identifies Solder Bond Failure as the Root Cause of Series Resistance Increase in Fielded Solar Modules

Correlating the electrical performance of photovoltaic modules to the spatially resolved photoluminescence, electroluminescence, and dark lock-in thermography (DLIT) images is an important long-term goal for developing solar cell technology. These images offer highly sophisticated and detailed information about the spatial distribution and (if imaged at successive time intervals) temporal degradation of local series and shunt resistances. There have been extensive studies to correlate these imaging techniques to local characteristics at the cell level. However, it has been difficult to extract and quantify module-level information from the techniques. In this study, we interpret module current-voltage (I-V) measurements along with corresponding DLIT images within a module-scale simulation framework, demonstrating that series resistance degradation of the module I-V characteristics, in this case, can be attributed to solder bond failures. Our simulations highlight how current crowding associated with a failed solder joint (or a section of the solder pad) translates to the characteristic point-like (asymmetric doublet) heating pattern in neighboring solder joints (or the neighboring regions of the solder pad). Overall, the correlation between series resistance and solder joint degradation could inform expedited diagnosis of field degradation of solar modules.

42 ENGINEERING↗
DOE OSTI2017

FY17 Status Report for the Development of Infrared Thermography for In-Pile Fuel Behavior Applications

Under a Department of Energy Office of Nuclear Energy (DOE-NE) initiative to develop in-pile instrumentation, an activity has been initiated to develop an infrared thermography (IRT) approach for in-reactor monitoring of fuel behaviors. The project will focus on leveraging mature, mainstream IRT techniques for use on nuclear fuel systems inside a nuclear reactor through unique adaptations for remote applications – an extremely challenging engineering and measurement objective – never before accomplished in-pile. To this end, some of the most important issues to be addressed include identifying an optimal IRT configuration (of many possible) and components for detecting specific structural evolutions such as fuel cracking and fuel void formation and migration; developing a long distance imaging system to transmit high resolution infrared images from a small specimen surface in the harsh environment of a reactor core to a IR camera or other detector array; and ultimately, integrating a complete experimental system to create a full in-reactor experiment. This document provides an overview of potential in-pile applications of IRT, a brief overview of IRT techniques, a detailed research plan and schedule for the project, and a summary of activities that have been initiated in the closing months of fiscal year 2017.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2019

PBX-9501 High Explosive Infrared Thermography Test Report

High explosive safety requirements put in place by the Department of Defense necessitate that Los Alamos National Laboratory verify that high melting explosive-based plastic bonded explosive 9501 will not present a health or safety risk to personnel when exposed to various accident scenarios. The JT5R-14C test is being developed to validate this requirement in a scenario where PBX-9501 is exposed to a hydrocarbon fuel fire. Preliminary testing is required to establish benchmark data on the burning characteristics of PBX-9501. The PBX-9501 High Explosive Infrared Thermography test was designed to provide the benchmark burning characteristics of PBX-9501 in a simulated fuel fire environment using propane burners as a fuel source. The PBX-9501-HEIT was successfully completed using a 20.32 cm tall cylindrical sample of PBX-9501 with a radius of 10.16 cm, a volume of 6,589.63 cm 3 , a density of 1.83 g/cm 3 , and a mass of 1.2 kg. The PBX-9501-HEIT test was captured and recorded video sequence using a Telops Inc., Multispectral Infrared camera. The infrared sequence was reviewed to identify key events throughout the test and serves as a visual tool to cross reference against future testing to aid in the identification of PBX-9501 high explosive ignition and deflagration characteristics. The data obtained in the thermographic sequence confirmed that the temperatures emitted by the PBX-9501 were higher than the temperatures of the propane burner ignition source. The propane burner flames had a temperature range of 700-850 °C. The cylindrical sample of PBX-9501 burned at an average temperature of 1000-1200 °C on the surface with off-gassing temperatures averaging 1100-1250 °C. The heat map of the PBX-9501 obtained through the test was between 250-550 °C higher than the propane gas temperatures. The temperature differential between the PBX-9501 and the propane flame allowed for the identification of key burning features.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗
NASA NTRSDate not supplied

Delamination Depth Imaging for Quasi-Static and Fatigue Load Testing Using Passive Thermography

Passive thermography is used to monitor small increases in temperature resulting from delamination damage formation in composite hat-stiffened panels during both quasi-static and fatigue loading. It has been observed that rapid damage formation produces heating. This is composed of two heat generation components. The first component is an instantaneous response due to an irreversible thermoelastic strain release. The second component is mechanical heating, at the interface of failure, due to fracture damage. This produces a transient rise in temperature as the heat diffuses to the surface. The first component defines the thermal start time for the transient response. A one-dimensional thermal model is fitted to the data pixel by pixel, to produce imagery of the damage depth. The results are compared to ultrasonic and X-ray CT data.

Passive thermography↗
NASA NTRSDate not supplied

Characterization of Composite Damage Using Passive Thermography

Passive thermography is used to monitor small increases in temperature on a composite structure during loading. A rise in temperature can be attributed to damage formation due to matrix cracking and fiber breaks. An infrared camera allows for imaging the damage location, size, and shape. Recently, a technique has been developed to estimate the depth of the damage in a composite hat-stiffened panel during quasi-static loading. This technique is based on two heat generation components. The first component is an instantaneous thermoelastic response due to a strain release. The second component is mechanical heating, at the interface of failure, due to fracture damage. This second component produces a transient rise in temperature that is a function of the damage depth and thermal diffusivity. The first component defines the thermal start time for the transient response. A one-dimensional thermal model is used to determine the damage depth for a known thermal diffusivity. The results are compared to ultrasonic and X-ray CT data and show good agreement for damage depth.

Thermal nondestructive evaluation↗
NASA NTRSDate not supplied

Progress on Quantitative Infrared Thermography at the NASA Langley Aerothermodynamic Laboratory

A quantitative infrared thermography technique is being developed for accurate and high-resolution measurements of surface temperature and heat flux in the hypersonic wind tunnels at NASA Langley Research Center. A hemisphere test campaign was carried out in the Langley Aerothermodynamic Laboratory 20-Inch Mach 6 Air Tunnel to assess the current performance of the technique and to identify remaining challenges. Measurements were obtained for three different model materials over a range of freestream Reynolds numbers. The raw infrared images were converted to temperature via a radiometric calibration of the camera sensor. Corrections were made for losses due to test article emissivity and window transmissivity. A preliminary uncertainty analysis yielded an estimated accuracy within 4 K at moderate viewing angles, similar to that of a standard thermocouple. Surface heat flux was obtained from the measured surface temperatures via a finite-difference solution of the one-dimensional heat equation that modeled thermal variation of the material properties. Comparisons of the measured heating to both computational and theoretical predictions demonstrated agreement within the expected uncertainty of the technique. The heat transfer measurement near the stagnation point was found to be highly sensitive to the test article emissivity, which establishes the need for improved characterization of the wind tunnel model materials for high temperature applications.

infrared thermography↗
DOE OSTI2020

Real-time cure monitoring of fiber-reinforced polymer composites using infrared thermography and recursive Bayesian filtering

Despite the desirable characteristics of fiber-reinforced polymer (FRP) composites, their utilization in high volume production industries is limited by a lack of efficient manufacturing techniques. Monitoring the curing process of these composites can help with improving the quality and efficiency of the manufacturing process. This article discusses a method that uses Kalman-filter-based fusion of the information obtained from infrared thermography (surface temperature measurements) and a heat conduction model to estimate degrees of cure and internal temperatures of curing FRP composite parts in real time. The effectiveness of the methodology is demonstrated by successfully monitoring the curing of an FRP composite part in a laboratory experiment. Finally, the proposed methodology is a crucial step towards identifying anomalies in the curing process that negatively impact the quality of FRP composite parts.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Quantifying deformation during Zry-4 burst testing: a comparison of BISON and a combined in-situ digital image correlation and infrared thermography method

The development and verification of nuclear fuel-cladding performance codes require extensive testing to establish empirical correlations, necessitating more accelerated testing methods that can replace large validation studies. Here, in the present work, a technique was developed and implemented to experimentally quantify the relationship between temperature, cladding internal pressure, and strain in-situ during a burst test, with the specific aim of generating data for code validation and model refinement. Digital image correlation was used to measure hoop, axial, and radial strain, and infrared thermography to quantify axial temperature gradients. Several key experimental modifications to traditional LOCA burst testing were necessary, but are shown to effectively have little impact on burst temperatures. The time/temperature dependent pressure and time/spatially dependent thermal gradient data were used with BISON to simulate cladding burst and strain rates. Although the measured DIC strains reach appreciable amounts at slightly lower temperatures than BISON simulated strains, there is good agreement between the measured and simulated strains in terms of magnitude and rates leading up to burst. However, in the few seconds prior to and during burst, the BISON simulated strains are significantly lower than the measured strains, indicating the potential for model improvement. The combined experiment and simulation technique may be applied to any new cladding concept to accelerate fuel qualification.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Digital image correlation and infrared thermography data for seven unique geometries of 304L stainless steel

Material Testing 2.0 (MT2.0) is a paradigm that advocates for the use of rich, full-field data, such as from digital image correlation and infrared thermography, for material identification. By employing heterogeneous, multi-axial data in conjunction with sophisticated inverse calibration techniques such as finite element model updating and the virtual fields method, MT2.0 aims to reduce the number of specimens needed for material identification and to increase confidence in the calibration results. To support continued development, improvement, and validation of such inverse methods—specifically for rate-dependent, temperature-dependent, and anisotropic metal plasticity models—we provide here a thorough experimental data set for 304L stainless steel sheet metal. The data set includes full-field displacement, strain, and temperature data for seven unique specimen geometries tested at different strain rates and in different material orientations. Commensurate extensometer strain data from tensile dog bones is provided as well for comparison. We believe this complete data set will be a valuable contribution to the experimental and computational mechanics communities, supporting continued advances in material identification methods.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Advances in phosphor two-color ratio method thermography for full-field surface temperature measurements

We report thermographic phosphors can be employed for optical sensing of surface, gas phase, and bulk material temperatures through different strategies including the time-decay method, time-integrated method, and frequency-domain method. We focus on the time-integrated method, also known as the ratio method, as it can be more practical in many situations. This work advances the ratio method using two machine vision cameras with CMOS detectors for full-field temperature measurements of a solid surface. A phosphor calibration coupon is fabricated using aerosol deposition and employed for in situ determination of the temperature-versus-intensity ratio relationship. Algorithms from digital image correlation are employed to determine the stereoscopic imaging system intrinsic and extrinsic parameters, and accurately register material points on the sample to subpixel locations in each image with 0.07 px or better accuracy. Detector nonlinearity is carefully characterized and corrected. Temperature-dependent, spatial non-uniformity of the full-field intensity ratio—posited to be caused by a blue-shift effect of the bandpass filter for non-collimated light and/or a wavelength-dependent transmission efficiency of the lens—is assessed and treated for cases where a standard flat-field correction fails to correct the non-uniformity. In sum, pixel-wise calibration curves relating the computed intensity ratio to temperature in the range of T = 300–430 K are generated, with an embedded error of less than 3 K. This work offers a full calibration methodology and several improvements on two-color phosphor thermography, opening the door for full-field temperature measurements in dynamic tests with deforming test articles.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗