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Results for “nondestructive examination”

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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72 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Surface Stress Characterization and Trends in Thermally Strengthened Photovoltaic Module Glass

Simultaneous changes in photovoltaic (PV) module architecture-such as increased area, replacing the polymeric backsheet with a glass backsheet, and reducing glass thickness from 3.2 to 2.0 mm-have resulted in a novel failure called spontaneous glass breakage. Spontaneous glass breakage results in front and/or rear glass failure without any obvious cause. The resulting low-energy fracture patterns have raised concerns about the thermal strengthening in 2.0-mm glass. We present validation of a nondestructive method for measuring the glass surface stress in PV modules. We use a scattered light polariscope to examine the glass properties of 11 modules from 6 solar fields, with and without spontaneous glass breakage. Based on a Mann-Whitney test p-value of 1.4 x 10-6, we conclude that there is a correlation between lower surface stress and susceptibility to spontaneous breakage. A Kendall's Tau test p-value of 2.0 x 10-4 indicates a correlation between increased module area and lower surface stress. We find that 2.0-mm glass can be, and often is, fully tempered (surface stress ≥69 MPa), but inspecting the fracture pattern is not a reliable way to assess the amount of thermal strengthening. A combination of factors, not just surface stress, influences glass breakage.

14 SOLAR ENERGY↗
DOE OSTI2024

High Speed Impact Testing of UHMWPE Composite Using Orthogonal Arrays

Abstract Background Ultra high molecular weight polyethylene composites are fiber based composites used in armor applications. While some characterization has been conducted experimentally, this study varies multiple parameters simultaneously to investigate material response under a wide range of conditions. Objective This work focuses on characterizing the response of Dyneema ® HB26 hard laminate composites under high-speed impacts to examine the influence of plate diameter, clamping pressure, and plate spacing on target performance. Additionally, micro Computer Tomography scans are used to nondestructively evaluate the damage evolution in the targets. Methods These scan results are used in concert with more traditional armor performance metrics to evaluate the effect of various parameters using the method of orthogonal array analysis. This technique allows for multiple variables to be investigated in the same test series, saving time and budget while still providing quality results across a range of variables and variable values. Results We conclude that of the parameters investigated, the plate spacing parameter has the largest effect on performance, followed by the plate diameter. Bolt torque was found to not have a significant impact on results, indicating that an edge clamping pressure is not critical to material response. Additionally, by examining the high resolution scans, we can quantify the damage with an effective damage angle and that this angle is a good predictor of performance. Conclusion Finally a damage theory involving the effective bending strength of the plates is discussed as an explanation for all of the results observed in this test series.

Hannah, T. (ORCID:0000000230261362)↗
DOE OSTI2023

Seeing the whole picture: Methods for getting the most from micro X-ray computed tomography of TRISO nuclear fuel particles

Tristructural isotropic (TRISO) coated fuel particles are a nuclear fuel form under extensive study for use in advanced nuclear reactor concepts. TRISO fuels are subjected to high temperature neutron irradiations and then examined to assess their performance by determining fission product retention and studying morphological changes. Micro X-ray computed tomography is one method of nondestructively studying the effects of TRISO performance. This work addresses the need for image processing to remove X-ray tomographic reconstruction artifacts that prevent the study of TRISO features, as the TRISO particles’ high Z kernel can introduce metal artifacts that degrade the image quality in the surrounding low Z coating layers. These metal artifacts were reduced by imaging the TRISO particles with both high- and low-energy X-rays and applying a mask to the radiographs obtained with low-energy X-rays to digitally remove the dense fuel kernel region. These masked radiographs were then used to produce a tomographic reconstruction which was combined with the tomographic reconstruction of the high-energy data. This enabled the relatively-low-density TRISO buffer layer to be examined in more detail, providing information on irradiation induced dimensional changes of the coatings. This methodology, which helps see the full picture of a TRISO particle, is not limited to nuclear fuels but can be applied to systems that contain highly attenuating material surrounded by less dense materials.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2022

Initial Refinement and Optimization of the Image Reconstruction (U-MBIR) Algorithm to Optimize its Performance in Detecting Damage and Flaws

Concrete is a critical component of nuclear power plants; thus, its safety and reliability must be thoroughly examined throughout the life cycle of the structural system. During the life cycle of this infrastructure, monitoring of the concrete for signs of degradation should be performed through nondestructive evaluation (NDE). Ultrasonic measurements have been an industry standard for both surface and subsurface inspections. As such, Oak Ridge National Laboratory (ORNL) is developing advanced image reconstruction algorithms to overcome the limitations of traditional ultrasonic NDE methodologies. The results and discussion presented herein summarize the current state of the ultrasonic model–based iterative reconstruction (U-MBIR) algorithm developed at ORNL.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Evaluation of Machine Learning Models for Automated Data Analysis in In-Service Nuclear Power Plant Inspections

The commercial nuclear power industry is facing a potential shortage of certified nondestructive evaluation (NDE) analysts to meet future in-service inspection demands. Automated data analysis (ADA) currently supports human inspectors in tasks such as eddy current evaluations for steam generator examinations. Machine learning (ML) systems are nearing the capability to pass performance demonstration tests for ultrasonic testing (UT) inspections of reactor pressure vessel upper head penetrations in nuclear power plants (NPPs). Current research and development is focused on assisted analysis (AA) of ADA versus fully automated examinations. This presentation will cover assessment of ML flaw detection on dissimilar metal weld (DMW) piping joints.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Thermal impacts on nondestructive analysis measurements of uranium hexafluoride

A series of nondestructive assay measurements were performed before, during, and after localized heating of an industrial standard 12B cylinder of uranium hexafluoride to replicate dose variations previously observed on commercial 30B cylinders. While cylinders represent a closed system, enrichment measurements may be impacted by altered uranium and daughter product distributions due to sublimation. A series of measurements were performed to examine localized heating impacts on dose rates, ratios of uranium and daughter product distributions, and measured 235 U enrichment as calculated by two different approaches. The less complex enrichment meter approaches were found to be more robust and less prone to deviation than isotope ratio approaches such as FRAM, but the impact can be minimized by using observable dose changes to avoid impacted areas.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
DOE OSTI2022

Bioaccumulation of Mercury and Radiocesium in Waterfowl Introduced to a Site with Legacy Contamination

Despite the propensity of waterfowl species to readily accumulate anthropogenic contaminants within polluted environments, few studies have examined bioaccumulation rates over time when entering such a contaminated site. We examined mercury (Hg) and radiocesium ( 137 Cs) bioaccumulation over time in two waterfowl species released into a wetland system containing legacy contamination on the US Department of Energy's Savannah River Site in South Carolina. Released birds were collected at select time intervals over an exposure period of 94 days. We quantified total Hg concentrations in blood, muscle, and liver tissues, and 137 Cs activity in whole-body and muscle tissues. The relationship between the contaminant burdens of different body tissue types was examined over time. Likely a result of microhabitat selection, mallards in our study readily accumulated both Hg and 137 Cs at consistent rates over time within our study system, while ring-neck ducks did not. The findings demonstrated that whole blood can be used as a robust, nondestructive sampling alternative to estimate Hg burdens within muscle and liver, and whole-body 137 Cs activity is a good predictor of muscle burdens. Understanding such bioaccumulation information in waterfowl is useful for the assessment of the potential health risk in wildlife, as well as being important for human risk assessment toward the consumption of popular game species. Environ Toxicol Chem 2022;41:2479–2487. © 2022 The Authors. Environmental Toxicology and Chemistry published by Wiley Periodicals LLC on behalf of SETAC.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2022

Coordinated neutron and X-ray computed tomography of meteorites: Detection and distribution of hydrogen-bearing materials

The presence and distribution of hydrogen-bearing materials in meteorites are important constraints on processes in the early solar system, and the delivery of volatile constituents to growing planets. Here, in this paper, we show that coordinated neutron and X-ray computed tomography, NXCT, can reveal the presence and distributions of hydrogen-bearing materials in meteorites, and thus help constrain the presence and actions of water in the early solar system. NXCT is nearly nondestructive of meteorite samples. Neutron fluence in NXCT is approximately seven orders of magnitude less than in typical instrumental neutron activation analysis, and so produces little residual radioactivity and currently undetectable changes in isotope ratios. Heating during NXCT is minimal, but NXCT will overprint the record of cosmic ray exposure held in natural thermoluminescence. Two meteorites were examined. EET 87503 is a howardite, a regolith breccia inferred to be from the asteroid 4 Vesta, and contains fragments of eucrite basalt, diogenite pyroxenite, and H-rich carbonaceous chondrites. With NXCT, the chondrite fragments within the meteorite piece can be clearly located and characterized, in preparation for possible extraction and detailed analyses. Graves Nunataks (GRA) 06100 is a CR2 chondrite meteorite that contains abundant iron metal and H-bearing silicates from aqueous alteration. In NXCT, H-bearing altered material is clearly distinguished from metal, and its distribution in three dimensions is revealed as a constraint on the processes of alteration.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2023

Irradiation of ultrasonic sensors and adhesive couplants for application in light water reactor primary loop piping and components

The Electric Power Research Institute (EPRI) Nuclear Sector and US Department of Energy Light Water Reactor Sustainability Program are committed to engaging in research and development endeavors to address materials aging issues specific to long term operation of light water power reactors. To this effect, EPRI launched an industry initiative to develop nondestructive evaluation systems for online monitoring of existing cracks in light water reactor primary coolant loop piping and components. One of the goals of this initiative is to develop a sensor system (or systems) that can determine nondestructively if cracks are growing or arrested and, in the case of the former, to characterize their growth rates. A missing component of this initiative is an experimental assessment of how sensors and adhesive couplants will perform in service when exposed to chronic energetic neutron radiation, particularly at the primary coolant loop hot and cold leg dissimilar metal welds, which join the primary loop piping to the reactor pressure vessel and reside in the vicinity of the reactor core. The objective of this experimental study was to determine how ultrasonic transducers and adhesive couplants perform when exposed to irradiation in a test reactor to simulate and accelerate in-service exposure. Further, to achieve this objective, the signal stability of piezoelectric transducers and performance of adhesive couplants as a function of accumulated fast neutron fluence were characterized by collecting ultrasonic data in-situ during irradiation. Of particular interest were the ultrasonic signal quality and time decay of the amplitude of acoustic reflections as a function of fast neutron fluence. The results of the study showed that, of the 8 transducer/substrate sample assemblies tested, only 3 generated usable ultrasonic signals through the conclusion of the irradiation campaign. It was found that high temperature epoxy tends to ultrasonically couple the sensors to the substrates better than three types of refractory ceramic cements studied, as is supported by post irradiation examination. The results obtained through this experimental study will be utilized in the achievement of the overall goal of development of a sensor system to perform online monitoring of primary loop components.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Ultrasonic nondestructive evaluation of additively manufactured wear coatings

Here, this work pertains to the nondestructive evaluation of additively deposited coatings using ultrasound measurements. The specific objective was to evaluate using ultrasound surface wave measurements the quality of Stellite 21 coatings deposited on Inconel 718 substrates by the directed energy deposition (DED) additive manufacturing (AM) process. The surface wave speed and diffuse backscatter amplitude of the ultrasound waves were correlated with both cracking and warpage of the coating. This research is important, because, the integrity of DED-processed coatings currently requires a combination of destructive metallographic studies and X-ray computed tomography analysis, which are both expensive and time consuming. Instead of using a normal incidence configuration for the ultrasound measurements, the surface-wave approach allows the inspection of the near surface coating integrity. Three different frequencies were used to excite surface waves because each frequency has a different penetration depth. The signals obtained were used to quantify and compare the surface wave speed and surface wave-diffuse ultrasonic backscatter amplitude from five different DED-processed Stellite coated samples. Considering destructive metallurgical characterization as a reference, surface wave measurements were found to be effective for examining coating integrity. Further, the backscatter amplitude of the surface waves was correlated with the crack density and warpage. These flaws also change the stress state of the Stellite coating and consequently the surface wave propagation speed and its scattering behavior.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Ultrasonic Elastography for Nondestructive Evaluation of Dissimilar Material Joints

Dissimilar material joints or multilayered metals have become inevitable in the manufacturing industry due to the increasing demand for multifunctional materials with variable mechanical, thermal, or electrical characteristics in a single assembly. Lattice mismatch of materials at the interface of dissimilar materials leads to inferior mechanical characteristics. In particular, the mismatch in elastic properties indicated by a large initial elastic deformation is critical to determine the extent of variation in stress. However, nanoindentation, the most common and accepted technique to measure elastic modulus, is destructive, time-consuming, and can only examine mechanical properties within a limited area. A non-invasive elastographic mapping technique evaluates the mechanical properties using ultrasonic elastography to study incompressibility. The dissimilar joint between steel and copper was obtained via friction stir welding. The variation of the stress developed at the welded joint of the two different metals was evaluated from the dynamic bulk modulus map. A tensile test of the involved workpiece confirmed a good agreement with our analysis based on the dynamic bulk modulus elastographic mapping results. This study provides a rapid and non-invasive technique for the bulk metallurgic elastic modulus inspection to overcome the limitations of conventional methods.

Jin, Yuqi↗
DOE OSTI2024

Nondestructive Analysis of Commercial Batteries

Electrochemical batteries play a crucial role for powering portable electronics, electric vehicles, large-scale electric grids, and future electric aircraft. However, key performance metrics such as energy density, charging speed, lifespan, and safety raise significant consumer concerns. Enhancing battery performance hinges on a deep understanding of their operational and degradation mechanisms, from material composition and electrode structure to large-scale pack integration, necessitating advanced characterization methods. These methods not only enable improved battery performance but also facilitate early detection of substandard or potentially hazardous batteries before they cause serious incidents. Here, this review comprehensively examines the operational principles, applications, challenges, and prospects of cutting-edge characterization techniques for commercial batteries, with a specific focus on in situ and operando methodologies. Furthermore, it explores how these powerful tools have elucidated the operational and degradation mechanisms of commercial batteries. By bridging the gap between advanced characterization techniques and commercial battery technologies, this review aims to guide the design of more sophisticated experiments and models for studying battery degradation and enhancement.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Seeing through nuclear fuel: Three-dimensional, nondestructive X-ray microscopy and volumetric analyses of neutron-irradiated TRISO-coated fuel kernels

The three-dimensional (3D) characterization of nuclear fuel with X-ray microscopy has historically proven difficult, due to uranium’s high attenuation of easily accessible X-rays, both in a laboratory setting and at a synchrotron user facility. However, this imaging modality provides nondestructive information that can be used to investigate morphological changes arising from external stimuli (e.g., neutron irradiation, high-temperature testing). Using an appropriate X-ray energy spectrum and an adequate X-ray filter, suitable transmissions through properly sized nuclear fuel specimens can be achieved. Here, in this study, we present the methods and results of using a commercially available, laboratory-based X-ray microscope (XRM) to examine the extent of 3D morphological changes of tristructural isotropic (TRISO)-coated fuel particles, specifically uranium oxide/uranium carbide fuel kernels, after high-temperature neutron irradiation.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Scanning transmission x-ray microscopy (STXM) of plutonium oxide

Scanning transmission x-ray microscopy was used to examine plutonium oxide particles formed by the corrosion of δ-phase plutonium alloy under high-humidity conditions. O K-edge spectra collected from eight distinct particles displayed significant spectral differences, revealing heterogeneity in oxidation states within a single sample batch. Here, this variation suggests complex chemical environments and formation histories, which are important considerations for nuclear forensic investigations. These findings highlight both the potential of synchrotron-based x-ray microscopy for nondestructive, high-resolution analysis of nuclear materials and the need for expanded reference datasets to improve the interpretation and forensic utility of such measurements.

organic↗
DOE OSTI2022

Monitoring accelerated alkali-silica reaction in concrete prisms with petrography and electrical conductivity measurements

We report deterioration of concrete due to alkali-silica reaction (ASR) involves a reaction between alkaline ions in the cement pore solution and non-crystalline silica found in many aggregates. Diagnosing and quantifying deterioration due to ASR in concrete currently requires destructive testing for microscopy examinations. In this paper, electrical conductivity is investigated qualitatively as an alternative non-destructive evaluation (NDE) method of ASR in hardened concrete. The study was performed using an unrestrained set of small concrete prism specimens made with highly reactive small aggregates, and kept in an environmental chamber according to ASTM C1293 standard. In a companion study, destructive petrography and damage rating index (DRI) assessment, and pore solution extraction and analysis were performed on the same set of accelerated ASR specimens. The results show that temporal evolution of nondestructive bulk resistivity is linearly correlated with destructive DRI score.

36 MATERIALS SCIENCE↗
DOE OSTI2021

AI-Enabled Robotic NDE for Structural Damage Assessment and Repair

The aim of this paper is to develop the concept and a prototype of an intelligent mobile robotic platform that is integrated with nondestructive evaluation (NDE) capabilities for autonomous live inspection and repair. In many industrial environments, such as the application of power plant boiler inspection, human inspectors often have to perform hazardous and challenging tasks. There is a significant chance of injury, considering the confined spaces and limited visibility of the inspection environment and hazards such as pressurization and improper water levels. In order to provide a solution to eliminate these dangers, the concept of a new robotic system was developed and prototyped that is capable of autonomously sweeping the region to be inspected. The robot design contains systematic integration of components from robotics, NDE, and artificial intelligence (AI). A magnetic track system is used to navigate over the vertical steel structures required for examination. While moving across the inspection area, the robot uses an NDE sensor to acquire data for inspection and repair. This paper presents a design of a portable NDE scanning system based on eddy current array probes, which can be customized and installed on various mobile robot platforms. Machine learning methods are applied for semantic segmentation that will simultaneously localize and recognize defects without the need of human intervention. Experiments were conducted that show the NDE and repair capabilities of the system. Improvements in human safety and structural damage prevention, as well as lowering the overall costs of maintenance, are possible through the implementation of this robotic NDE system.

Materials Science↗
DOE OSTI2023

Material Plasma Exposure eXperiment High Heat Flux Microwave Absorber Design, Manufacture, and Articles Test

The Material Plasma Exposure eXperiment (MPEX) at Oak Ridge National Laboratory is in the final design phase. MPEX will be capable of exposing neutron-irradiated materials to plasmas for the study of plasma-material interaction. This facility will provide information about the complex effects of plasmas on materials and contribute to examining new materials that can withstand high heat fluxes and high ion fluences for future fusion devices. MPEX plasma is heated by 70-GHz or 105-GHz electron Bernstein wave/electron cyclotron heating (ECH), and the high-frequency microwaves are prone to scattering microwave power, which can have detrimental effects, especially on diagnostic components. A large portion of the injected ECH power is expected to be absorbed by plasma, but the remainder requires that microwave absorbers be placed immediately upstream and downstream of the ECH launcher to minimize stray microwaves leaving the ECH region. These microwaves can inadvertently heat components that cannot be shielded or otherwise protected. The microwave absorber design is based on an array of pyramid-shaped ceramic tiles brazed to a water-cooled explosion-bonded heat sink and a stainless steel plate to produce one tile module. Computational fluid dynamics and structural analyses were performed to optimize and validate the design. Multiple test coupons were produced to validate the process for brazing the two different tile materials to the Glidcop AL-15 baseplate. The articles were tested to evaluate the reliability and thermal performance through exposure to an electron beam with a heat flux of up to 1.5 MW/m2. Nondestructive testing was performed before and after testing to identify voids or separations that may have been introduced by the high heat flux. This paper discusses the details of high heat flux microwave absorber design, manufacturing details and associated challenges, and test results, demonstrating the effectiveness of the proposed design.

Hussain, Aftab↗
DOE OSTI2025

All the light we cannot see: Climate manipulations leave short and long‐term imprints in spectral reflectance of trees

Abstract Anthropogenic climate change, particularly changes in temperature and precipitation, affects plants in multiple ways. Because plants respond dynamically to stress and acclimate to changes in growing conditions, diagnosing quantitative plant‐environment relationships is a major challenge. One approach to this problem is to quantify leaf responses using spectral reflectance, which provides rapid, inexpensive, and nondestructive measurements that capture a wealth of information about genotype as well as phenotypic responses to the environment. However, it is unclear how warming and drought affect spectra. To address this gap, we used an open‐air field experiment that manipulates temperature and rainfall in 36 plots at two sites in the boreal‐temperate ecotone of northern Minnesota, USA. We collected leaf spectral reflectance (400–2400 nm) at the peak of the growing season for three consecutive years on juveniles (two to six years old) of five tree species planted within the experiment. We hypothesized that these mid‐season measurements of spectral reflectance capture a snapshot of the leaf phenotype encompassing a suite of physiological, structural, and biochemical responses to both long‐ and short‐time scale environmental conditions. We show that the imprint of environmental conditions experienced by plants hours to weeks before spectral measurements is linked to regions in the spectrum associated with stress, namely the water absorption regions of the near‐infrared and short‐wave infrared. In contrast, the environmental conditions plants experience during leaf development leave lasting imprints on the spectral profiles of leaves, attributable to leaf structure and chemistry (e.g., pigment content and associated ratios). Our analyses show that after accounting for baseline species spectral differences, spectral responses to the environment do not differ among the species. This suggests that building a general framework for understanding forest responses to climate change through spectral metrics may be possible, likely having broader implications if the common responses among species detected here represent a widespread phenomenon. Consequently, these results demonstrate that examining the entire spectrum of leaf reflectance for environmental imprints in contrast to single features (e.g., indices and traits) improves inferences about plant‐environment relationships, which is particularly important in times of unprecedented climate change.

Stefanski, Artur [Department of Forest Resources U↗