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At least 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Advances in Image-Domain Multi-Resolution and Super-Resolution Algorithms for Industrial X-Ray Computed Tomography: A Literature Survey and New Insights

Industrial X-ray Computed Tomography (XCT) is a nondestructive method for inspection and character ization of materials and parts. XCT captures images of a part from various angles, and these images are then used to construct Three-Dimensional (3D) representations of that part. This method enables assessing the quality of the parts, identifying defects and understanding their physical properties without damaging them.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Identifying the Accuracy of Surface Roughness for Metal Additive Manufacturing Parts Captured with Computed Tomography Scanning

Conventional surface roughness measurement techniques require direct access to internal surfaces, often necessitating destructive sectioning of test articles. Computed tomography (CT) offers a non-destructive alternative for internal surface characterization, but its application in metrology remains unstandardized and sensitive to machine resolution and operator technique. This study investigates the feasibility of using CT scanning to quantify areal surface roughness in metal AM heat exchanger tubes with three distinct internal geometries: ribbed, discrete W, and featureless. CT-derived surface parameters were extracted using custom Python scripts and compared to measurements obtained from a focus variation microscope calibrated against a known standard. Results show that CT-based roughness measurements closely matched microscope values for the discrete W specimen, deviations between CT and microscope measurements were minimal—less than 1 µm—indicating reliable reconstruction. In contrast, the ribbed and featureless specimens, with lower roughness values showed greater discrepancies. The findings suggest that CT scanning can be a viable non-destructive metrology tool for AM parts with surface roughness above approximately 8 µm. For smoother surfaces, current CT capabilities may not provide sufficient accuracy, highlighting the need for resolution-aware workflows and further standardization in CT-based surface metrology.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Development of low temperature fuel cell holders for Operando x-ray micro and nano computed tomography to visualize water distribution

Abstract Synchrotron x-ray imaging techniques, like x-ray computed tomography (CT) and radiography have proven instrumental in expanding the communities knowledge of complex transport and reaction kinetics in electrochemical devices such as fuel cells and electrolyzers. This work presents the development of novel x-ray CT imaging techniques for operando visualization of water within low temperature fuel cells at spatial resolutions spanning the micro and nano scales. The design of operando sample holders, for both micro x-ray CT and nano CT experiments is described in depth, and prototypes of these sample holders were evaluated across a set of requirements, the most important of which are x-ray transmissibility, electrical conductivity and mechanical stability. Water segmentation from micro x-ray CT data was enabled by an image subtraction method, where the image without water is subtracted from the one with water. Through iterative experimentations, the operando nano CT cell was developed to optimize mechanical compression, electric conductivity and gas flow. While three-dimensional fuel cell reconstructions were shown possible, there remain challenges to overcome at typical lower energies (8 keV) due to beam damage, whereas it is not as significant for higher energies (>17.5 keV).

Kulkarni, Devashish↗
DOE OSTI2023

Coregistered positron emission particle tracking (PEPT) and X-ray computed tomography (CT) for engineering flow measurements

Increasingly, fully 3D experimental measurements of flow in complex engineering geometries are required to validate computational fluid dynamics models that support and inform reactor design and licensing. One barrier to such measurements is the complexity of typical reactor components and subsequent lack of optical access in these systems. To overcome this, the deployment of coregistered positron emission particle tracking (PEPT) and X-ray computed tomography (CT) is explored for flow measurement in reactor thermal hydraulic components and model (scaled) systems. Through this methodology, fully 3D flow information (via PEPT) and detailed internal geometry (via CT) are captured in opaque systems such as pipes, rod bundles, packed beds, etc. The reconstructed flow field and geometry can then be overlain to reveal detailed flow features around internal structures within a given test section. This is enabled through the use of a combined preclinical PET/CT scanner with overlapping PET and CT fields of view. Such measurements are useful for characterizing flow inside such intricate nuclear thermal hydraulic components as core geometries and heat exchangers, among others, and providing valuable 3D validation data for CFD models. In this work, basic tests of this 3D flow/geometry mapping are presented, and the implications of such measurements are discussed. Further, preliminary measurements are made with both point sources and flow in a simple pipe flow geometry to evaluate the capabilities of this technique. PEPT and CT features are coregistered with up to 0.1 mm precision, and pipe flow mean velocity and Reynolds stresses are reconstructed with similar accuracy to previous PEPT demonstrations. The utility of PEPT/CT is shown herein, and suggestions for future measurements are made.

3D flow measurement↗
DOE OSTI2022

Computed Tomography Scanning and Geophysical Measurements of the Wellington 1-32 Core

The computed tomography (CT) facilities and the Multi-Sensor Core Logger (MSCL) at the U.S. Department of Energy’s (DOE), National Energy Technology Laboratory (NETL) in Morgantown, West Virginia were used to characterize core from the Wellington 1-32 well (API 15-191-22591), a small-scale field test site in the Wellington Field, in Sumner County, Kansas. Wellington 1-32 was drilled in association with the Kansas Geologic Survey’s (KGS) Phase I pre-feasibility study under the DOE-NETL Carbon Storage Assurance Facility Enterprise (CarbonSAFE) program, with the goal of utilizing the Arbuckle Group as a reservoir for CO 2 storage and the potential for stacked reservoir enhanced oil recovery from Mississippian reservoirs.

58 GEOSCIENCES↗
DOE OSTI2019

Investigation of Computational Corrections to X-Ray Computed Tomography for Dimensional Metrology of Complex Additively Manufactured Parts

X-ray computed tomography (CT) is a nondestructive evaluation technique that may be used to image complex internal features without the line-of-sight restrictions inherent in conventional optical and contact (stylus) metrology instrumentation. Applications of CT metrology include material defects (porosity), dimensions and surface texture. However, scan artifacts, such as streaking, caused primarily by beam hardening and scatter, limit the accuracy of CTbased metrology. Reduction of these artifacts would improve the accuracy material properties and dimensional metrology information. This paper reports on the development of additively manufactured (AM) Ti5553 and 316L measurement phantoms with integral lattice (lattice) structures specifically designed to exhibit these artifacts. The phantoms were scanned in three CT systems and a scanning-probe CMM measurement. Surfaces generated from uncorrected CT data exhibited “dimple” defects that are not present in the CMM measurement. Correction methods were developed in Livermore Tomography Tools (LTT) software and this paper reports on the successful correction of these artifacts. This work is expected to have application in areas where characterization of defects, dimensions and surface texture using CT are critical.

42 ENGINEERING↗
DOE OSTI2024

Computed Tomography Scanning and Petrophysical Measurements of Oriskany Core across Eastern Ohio

The computed tomography (CT) facilities and the Multi-Sensor Core Logger (MSCL) at the National Energy Technology Laboratory (NETL) in Morgantown, West Virginia were used to characterize core material from three Ohio wells. These wells are listed below along with their American Petroleum Institute (API) and Ohio Geological Survey (OGS) identification numbers: - New York Central System 1 well (API 34085200170000, OGS Core 855) - Herren Well (API 34099201650000, OGS Core 2914) - Garvin-King Well (API 34121215610000, OGS Core 2939) The primary impetus of this work was to capture a detailed digital representation of the available core from all three wells. The collaboration between the U.S. Department of Energy’s (DOE) NETL and the Ohio Department of Natural Resources, Division of Geological Survey enables other research entities to access information about this potential carbon storage location and its surrounding formations.

58 GEOSCIENCES↗
DOE OSTI2025

Reducing the Energy Consumption of Magnetic Resonance Imaging and Computed Tomography Scanners: Integrating Ecodesign and Sustainable Operations

This review aims to provide valuable insights into how energy consumption in magnetic resonance imaging (MRI) and computed tomography (CT) scanners can be effectively monitored, managed, and reduced, thereby contributing to more sustainable medical imaging practices. Demand for advanced imaging technologies such as MRI and CT scanners continues to increase, and understanding the resultant impact on greenhouse gas emissions requires a thorough evaluation of their energy consumption. Here, this review examines the energy monitoring and consumption characteristics of MRI and CT scanners, highlighting potential approaches for energy savings. An overview of MRI and CT principles, hardware components, and their associated energy consumption is provided. After addressing the technical aspects, the hardware and software requirements essential for accurate energy metering are detailed. Baseline measurements of energy consumption data are then provided as a foundation to understand current usage patterns and identify areas for improvement. Ongoing efforts to reduce energy consumption are categorized into 3 main strategies: operations, scanner design enhancements, and active scanning techniques, including accelerated MRI protocols. Ultimately, we emphasize that achieving sustainability in medical imaging requires collaboration across disciplines. By incorporating eco-friendly design in new imaging equipment, we can reduce the environmental impact, promote sustainability, and set a health care industry standard for a healthier planet.

62 RADIOLOGY AND NUCLEAR MEDICINE↗
DOE OSTI2025

Automated Image Segmentation and Processing Pipeline Applied to X–Ray Computed Tomography Studies of Pitting Corrosion in Aluminum Wires

Understanding pitting corrosion is critical, yet its kinetics and morphology remain challenging to study from X-ray computed tomography (XCT) due to manual segmentation barriers. To address this, an automated pipeline leveraging deep learning for efficient large-scale XCT analysis is developed, revealing new corrosion insights. The pipeline enables pit segmentation, 3D reconstruction, statistical characterization, and a topological transformation for visualization. Here, the pipeline is applied to 87 648 XCT images capturing commercial purity aluminum (1100 Al) wire exposed to sodium chloride (NaCl) salt particles over a period of 122 h. The pipeline achieves complete feature extraction and statistical quantification across the entire XCT dataset, leveraging distributed computing environment for high efficiency. Global growth kinetics such as high-level stepwise sigmoidal volume loss patterns and granular individual pit developments are both captured for 36 detected pits. By combining automation, computer vision, and extensive XCT datasets, this research accelerates precise corrosion assessment to enable materials science discoveries at scale.

36 MATERIALS SCIENCE↗
DOE OSTI2020

The application of synchrotron micro-computed tomography to characterize the three-dimensional microstructure in irradiated nuclear fuel

This research demonstrated the first time that synchrotron X-ray micro-computed tomography (μ-CT) was utilized to analyze the three-dimensional (3-D) morphology of the microstructure of irradiated nuclear fuel. Both absorption contrast and propagation-based phase contrast enhanced μ-CT techniques were evaluated. Porosity and phase region volumes were determined in neutron irradiated uranium 10 wt.% zirconium (U-10Zr) using propagation-based phase contrast enhanced μ-CT. Volumes were determined by image processing software and algorithms, with the porosity volume subsequently compared to the ASTM E562 method. The 3-D porosity of a small region (~ 8 x 10 5 µm 3 ) located in the intermediate fuel redistribution zone that was removed via a focused ion beam was determined to be 7.2% via image processing. A detailed 3-D analysis of the porosity with respect to volume and morphology was provided. Five growth stages of pore evolution were observed including: nucleation, growth, coalescence, interconnected porosity, and extended/interconnected porosity. Four distinct phase regions were identified, including the pores, via both absorption contrast and propagation-based phase contrast enhanced μ-CT. A quantitative comparison of fuel swelling between this localized microscopic U-10Zr fuel region, previously irradiated in the Fast Flux Test Facility, and historic U-10Zr fuels irradiated in the Experimental Breeder Reactor-II (EBR-II) was conducted. It was determined that for similar burnups, the localized swelling in this microscopic fuel region was 7.7%, which was approximately one-half of the value of the macroscopic swelling reported in EBR-II irradiated fuel. With the advent of new specimen preparation tools for irradiated materials, as well as advances in characterization techniques, researchers can now obtain previously inaccessible microstructural insight into irradiated fuels. This possibility naturally lends itself to improved fuel performance models for the nuclear community.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Computed Tomography Scanning and Geophysical Measurements of Core from the Boggess 17H Well

The computed tomography (CT) facilities and the Multi-Sensor Core Logger (MSCL) at the National Energy Technology Laboratory (NETL) in Morgantown, West Virginia were used to characterize the Marcellus Shale and underlying formations. The core is from a vertical pilot well (Boggess 17H) drilled in western Monongalia County near Core, West Virginia by Northeast Natural Energy for the second Marcellus Shale Energy and Environmental Laboratory (MSEEL). MSEEL is a joint venture between NETL, Northeast Natural Energy, and West Virginia University. The primary impetus for this report is to characterize the core to better understand the structure and variation of the Marcellus Shale and surrounding formations. This report, and the associated scans, provide detailed datasets not typically available from unconventional shales for analysis.

58 GEOSCIENCES↗
DOE OSTI2019

Interobserver agreement of computed tomography reporting standards for chronic pancreatitis

Aim: To assess the interobserver agreement of computed tomography (CT) reporting standards for chronic pancreatitis (CP). Subjects and methods: Retrospective analysis of CT of 47 patients (33 males and 11 females, age range 36 to 56 years) with CP who presented with abdominal pain (n = 41), steatorrhea (n = 37), and glucose intolerance (n = 31). The patients underwent CT study using a 16-multidetector CT scanner with a pancreatic protocol including a nonenhanced scan followed by pancreatic phase at 35 s and portal venous phase at 65 s after intravenous injection of nonionic contrast medium. Image analysis was performed by two radiologists according to reporting standards for CP. Results: There was excellent interobserver agreement (84.8 %) between the two reviewers in CT reporting standards for CP (K = 0.80, 95 % CI 0.75–0.85, P = 0.001). There was good interobserver agreement for pancreatic duct (PD) caliber (K = 0.71, 95 % CI 0.56–0.87, P = 0.001), PD contour (K = 0.76, 95 % CI 0.61–0.91, P = 0.001), PD stricture (K = 0.070, 95 % CI 0.53–0.88, P = 0.001), and distribution of findings (K = 0.69, 95 % CI 0.51–0.86, P = 0.001). There was excellent interobserver agreement for intraductal calculi (K = 0.84, 95 % CI 0.68–0.98, P = 0.001), pancreatic calcifications (K = 0.86, 95 % CI 0.84–0.98, P = 0.001), and pancreatic diameter (K = 0.87, 95 % CI 0.75–0.99, P = 0.001). Conclusion: CT reporting standards for CP is a reliable method for diagnosis of patients with CP.

62 RADIOLOGY AND NUCLEAR MEDICINE↗
DOE OSTI2023

Computed Tomography Scanning and Petrophysical Measurements of the Lively Grove #1 Well Core

The computed tomography (CT) facilities and the Multi-Sensor Core Logger (MSCL) at the National Energy Technology Laboratory (NETL) in Morgantown, West Virginia were used to characterize core from the Lively Grove #1 Well (API 121892494700), drilled near Marissa, Washington County, Illinois. Core from the well was obtained as part of the Illinois Storage Corridor’s Carbon Storage Assurance Facility Enterprise (CarbonSAFE) project (DE FE0031892). The primary impetus of this work was to capture a detailed digital representation of the core from the Lively Grove #1 Well. The collaboration between the U.S. Department of Energy’s (DOE) NETL and the Illinois State Geological Survey (ISGS) enables other research entities to access information about this potential carbon storage location and Cambro-Ordovician Storage Complex formations of the Illinois Basin. The resultant datasets are presented in this report and can be accessed from NETL’s Energy Data eXchange (EDX) online system. All equipment and techniques used were non-destructive, enabling future examinations and analyses to be performed on these cores. Fractures, discontinuities, and millimeter-scale features were readily detectable with the medical CT scanner-acquired images. Imaging with the NETL medical CT scanner was performed on entire cores. Qualitative analysis of the medical CT images, coupled with X-ray fluorescence (XRF), gamma density, and magnetic susceptibility measurements from the MSCL were useful in identifying zones of interest for potential future analysis. Higher-resolution industrial and micro-CT images were acquired from selected zones along the depth of the core to visualize the structure in higher detail. The ability to quickly identify key areas for more detailed study with higher resolution will save time and resources in future studies. The combination of methods used provides a multi-scale analysis of the core; with the resulting macro- and micro-descriptions relevant to many subsurface energy related examinations traditionally performed at NETL.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2020

3D microstructure design of lithium-ion battery electrodes assisted by X-ray nano-computed tomography and modelling

Driving range and fast charge capability of electric vehicles are heavily dependent on the 3D microstructure of lithium-ion batteries (LiBs) and substantial fundamental research is required to optimise electrode design for specific operating conditions. Here we have developed a full microstructure-resolved 3D model using a novel X-ray nano-computed tomography (CT) dual-scan superimposition technique that captures features of the carbon-binder domain. This elucidates how LiB performance is markedly affected by microstructural heterogeneities, particularly under high rate conditions. The elongated shape and wide size distribution of the active particles not only affect the lithium-ion transport but also lead to a heterogeneous current distribution and non-uniform lithiation between particles and along the through-thickness direction. Building on these insights, we propose and compare potential graded-microstructure designs for next-generation battery electrodes. To guide manufacturing of electrode architectures, in-situ X-ray CT is shown to reliably reveal the porosity and tortuosity changes with incremental calendering steps.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2021

Anisotropy evolution of elastomeric foams during uniaxial compression measured via in-situ X-ray computed tomography

We have characterized the three-dimensional evolution of microstructural anisotropy of a family of elastomeric foams during uniaxial compression via in-situ X-ray computed tomography. Flexible polyurethane foam specimens with densities of 136, 160 and 240 kg/m 3 were compressed in uniaxial stress tests both parallel and perpendicular to the foam rise direction, to engineering strains exceeding 70%. The uncompressed microstructures show slightly elongated ellipsoidal pores, with elongation aligned parallel to the foam rise direction. The evolution of this microstructural anisotropy during deformation is quantified based on the autocorrelation of the image intensity, and verified via the mean intercept length as well as the shape of individual pores. Trends are consistent across all three methods. In the rise direction, the material remains transversely anisotropic throughout compression. Anisotropy initially decreases with compression, reaches a minimum, then increases up to large strains, followed by a small decrease in anisotropy at the largest strains as pores collapse. Compression perpendicular to the foam rise direction induces secondary anisotropy with respect to the compression axis, in addition to primary anisotropy associated with the foam rise direction. In contrast to compression in the rise direction, primary anisotropy initially increases with compression, and shows a slight decrease at large strains. These surprising non-monotonic trends and qualitative differences in rise and transverse loading are explained based on the compression of initially ellipsoidal pores. Microstructural anisotropy trends reflect macroscopic stress-strain and lateral strain response. These findings provide novel quantitative connections between three-dimensional microstructure and anisotropy in moderate density polymer foams up to large deformation, with important implications for understanding complex three-dimensional states of deformation.

36 MATERIALS SCIENCE↗