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At least 757 records · Page 42

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DOE OSTI2020

Application and Certification of Comparative Vacuum Monitoring Sensors for Structural Health Monitoring of 737 Wing Box Fittings

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. The use of in-situ sensors for real-time health monitoring of aircraft structures are a viable option to 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. Prevention of unexpected flaw growth and structural failure can be improved if on-board health monitoring systems are used to continuously assess structural integrity. Such systems are able to detect incipient damage before catastrophic failures occurs. Condition-based maintenance practices could be substituted for the current time-based maintenance approach. Other advantages of on-board distributed sensor systems are that they can eliminate costly, and potentially damaging, disassembly, improve sensitivity by producing optimum placement of sensors and decrease maintenance costs by eliminating more time- consuming manual inspections. This report presents a Sandia Labs-aviation industry effort to move SHM into routine use for aircraft maintenance. 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. The Airworthiness Assurance NDI Validation Center (AANC) at Sandia Labs, in conjunction with Boeing, Delta Air Lines, Structural Monitoring Systems Ltd., Anodyne Electronics Manufacturing Corp. and the Federal Aviation Administration (FAA) carried out a certification program to formally introduce Comparative Vacuum Monitoring (CVM) as a structural health monitoring solution to a specific aircraft wing box application. 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 into an airline maintenance program and the document revisions necessary to allow for routine use of CVM as an alternate means of performing periodic structural inspects. To carry out the validation process, knowledge of aircraft maintenance practices was coupled with an unbiased, independent evaluation. Sandia Labs designed, implemented, and analyzed the results from a focused and statistically-relevant experimental effort to quantify the reliability of the CVM system applied to the Boeing 737 Wing Box fitting application. 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 CVM sensors in a manner that agrees with current nondestructive inspection (NDI) validation requirements and also is acceptable to both the aviation industry and regulatory bodies. This report presents the use of several different statistical methods, some of them adapted from NDI performance assessments and some proposed to address the unique nature of damage detection via SHM systems, and discusses how they can converge to produce a confident quantification of SHM performance An important element in developing SHM validation processes is a clear understanding of the regulatory measures needed to adopt SHM solutions along with the knowledge of the structural and maintenance characteristics that may impact the operational performance of an SHM system. This report describes the major elements of an SHM validation approach and differentiates the SHM elements from those found in NDI validation. The activities conducted in this program demonstrated the feasibility of routine SHM usage in general and CVM in particular for the application selected. They also helped establish an optimum OEM-airline-regulator process and determined how to safely adopt SHM solutions. This formal SHM validation will allow aircraft manufacturers and airlines to confidently make informed decisions about the proper utilization of CVM technology. It will also streamline the regulatory actions and formal certification measures needed to assure the safe application of SHM solutions.

42 ENGINEERING↗

DOE OSTI2022

Monitoring the daily evolution and extent of snow drought

Abstract. Snow droughts are commonly defined as below-average snowpack at a point in time, typically 1 April in the western United States (wUS). This definition is valuable for interpreting the state of the snowpack but obscures the temporal evolution of snow drought. Borrowing from dynamical systems theory, we applied phase diagrams to visually examine the daily evolution of snow water equivalent (SWE) and accumulated precipitation conditions in maritime, intermountain, and continental snow climates in the wUS using station observations as well as spatially distributed estimates of SWE and precipitation. Using a percentile-based drought definition, phase diagrams of SWE and precipitation highlighted decision-relevant aspects of snow drought such as onset, evolution, and termination. The phase diagram approach can be used in tandem with spatially distributed estimates of daily SWE and precipitation to reveal variability in snow drought type and extent. When combined with streamflow or other environmental data, phase diagrams and spatial estimates of snow drought conditions can help inform drought monitoring and early warning systems and help link snow drought type and evolution to impacts on ecosystems, water resources, and recreation. A web tool is introduced allowing users to create real-time or historic snow drought phase diagrams.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2026

Diagnosing Ghost Bunches with the Upstream Extinction Monitor in the Mu2e Experiment

The Mu2e experiment has a stringent requirement for extinction of the pulsed proton beam, referring to the elimination of particles between proton bunches to a relative level of 10$^-10$, which means a single out-of-time particle in the inter-pulse gaps for every 250 complete proton pulses. As the construction of the Mu2e experiment nears completion, it is crucially important to make an early measurement of the beam extinction in its current condition. Hence the upstream extinction monitor was constructed and operated to probe for problems in the proton pulse structure or a higher than expected incidence rate of out-of-time particles. The analysis in this work comes from data taken in March 2026. The long data run showed a significant presence of out-of-time particles from ghost bunches in the Delivery Ring approximately 388 ns after the centers of the main proton pulses. These are hypothesized to be the result of a combination of a RF frequency mismatch, particle space charge, and machine impedance during the rebunching sequence in the Recycler Ring, which can lead to particles leaking into adjacent buckets, but further studies and simulations are needed to confirm this

Hensley, R. [UC, Davis] (ORCID:0000000216064485)↗

NASA NTRS2003

Automated Monitoring with a BCP Fault-Decision Test

The Bayesian conditional probability (BCP) technique is a statistical fault-decision technique that is suitable as the mathematical basis of the fault-manager module in the automated-monitoring system and method described in the immediately preceding article. Within the automated-monitoring system, the fault-manager module operates in conjunction with the fault-detector module, which can be based on any one of several fault-detection techniques; examples include a threshold-limit-comparison technique or the BSP or SPRT technique mentioned in the preceding article. The present BCP technique is used to evaluate a series of one or more fault-detection events for the purpose of filtering out occasional false alarms produced by many types of statistical fault-detection procedures. The BCP technique increases the probability that an automated monitoring system produces a correct decision regarding the presence or absence of a fault. Because occasional false alarms are an inevitable consequence of the SPRT, BSP, or any other statistically based fault-detection test, there is a need for a logical procedure to distinguish between true and false alarms. Heretofore, it has been common practice to make a fault decision on an ad hoc basis for example by following a multiple-observation voting strategy in which a signal is declared to be indicative of a fault if m of the last n observations produced a fault-detection alarm. The BCP technique was developed to obtain results more reliable than those afforded by a voting strategy. The BCP technique involves a test in which one applies Bayesian inference techniques to a series of one or more single-observation alarms produced by a fault-detection test. One considers the last n decisions generated by a fault-detection test in order to evaluate the conditional probability that a failure is indicated (see figure). Each new decision reached by a fault-detection test is treated as a new piece of evidence about the state of the monitored asset, and the conditional probability of failure for the system is updated on the basis of this new evidence. The conditional probability of failure is compared with a predefined limit. For a probability below the limit, the asset is declared to be healthy. For a probability above the limit, the asset is declared to be faulty.

Bickford, Randall L.↗

NASA NTRS2015

Random Vibration Testing of Advanced Wet Tantalum Capacitors

Advanced wet tantalum capacitors allow for improved performance of power supply systems along with substantial reduction of size and weight of the systems that is especially beneficial for space electronics. Due to launch-related stresses, acceptance testing of all space systems includes random vibration test (RVT). However, many types of advanced wet tantalum capacitors cannot pass consistently RVT at conditions specified in MIL-PRF-39006, which impedes their use in space projects. This requires a closer look at the existing requirements, modes and mechanisms of failures, specifics of test conditions, and acceptance criteria. In this work, different lots of advanced wet tantalum capacitors from four manufacturers have been tested at step stress random vibration conditions while their currents were monitored before, during, and after the testing. It has been shown that the robustness of the parts and their reliability are mostly due to effective self-healing processes and limited current spiking or minor scintillations caused by RVT do not increase the risk of failures during operation. A simple model for scintillations events has been used to simulate current spiking during RVT and optimize test conditions. The significance of scintillations and possible effects of gas generation have been discussed and test acceptance criteria for limited current spiking have been suggested.

cracking↗

NASA NTRS2015

Random Vibration Testing of Advanced Wet Tantalum Capacitors

cracking↗

NASA NTRS2015

Random Vibration Testing of Advanced Wet Tantalum Capacitors

wet tantalum capacitors↗

NASA NTRS1993

Performance consequences of automation-induced 'complacency'

The effect of variations in the reliability of an automated monitoring system on human operator detection of automation failures was examined in two experiments. For four 30-min sessions, 40 subjects performed an IBM PC-based flight simulation that included manual tracking and fuel-management tasks, as well as a system-monitoring task that was under automation control. Automation reliability - the percentage of system malfunctions detected by the automation routine - either remained constant at a low or high level over time or alternated every 10 min from low to high. Operator detection of automation failures was substantially worse for constant-reliability than for variable-reliability automation after about 20 min under automation control, indicating that the former condition induced 'complacency'. When system monitoring was the only task, detection was very efficient and was unaffected by variations in automation reliability. The results provide the first empirical evidence of the performance consequences of automation-induced 'complacency'. We relate findings to operator attitudes toward automation and discuss implications for cockpit automation design.

Parasuraman, Raja↗

DOE OSTI2024

A Novel Concentrating Solar Weathering Apparatus for Experimental Validation of Multi-Modal Degradation Models

High-performance coatings for Concentrating Solar Power (CSP) receivers are subjected to remarkable environmental stressors during normal operations. Applied to the receiver tubes, these coatings serve to maximize the solar absorptivity of the receiver, transferring as much heat as possible from the solar collectors into the heat-transfer fluid (HTF). The lifecycle of these coatings is not well-defined, and the harsh operational conditions make them difficult to test. NREL has designed, built, and tested an apparatus to expose these samples to design levels of environmental stress and well beyond, into accelerated and destructive conditions. The chamber is actively cooled, monitored, and has the capability to supply humidification for cycling tests, allowing us to test multi-modal degradation and failure conditions at high temperature, high flux, and high humidity conditions. These conditions can catalyze high-temperature oxidation, mechanical degradation, and other modes of absorptivity loss seen in selective solar receiver coatings. The experimental data can feed lifecycle models for expensive and necessarily resilient materials, offering insights to aid maintenance schedules, technoeconomic analysis, and material industry performance benchmarks. This presentation will demonstrate the apparatus design and performance, as well as initial results for aging on a selective receiver coating.

14 SOLAR ENERGY↗

DOE OSTI2021

Microscopic assessment of ASR-affected concrete under confinement conditions

The Damage Rating Index (DRI), a semi-quantitative microscopic procedure, has been successfully used to describe alkali-silica reaction (ASR) damage development of concrete under “free expansion” conditions. Yet, the confinement impact on ASR-induced cracks' generation and propagation has not been fully investigated. This work aims to understand the influence of confinement on ASR development through the DRI. Eighteen concrete blocks incorporating a highly reactive coarse aggregate and distinct reinforcement configurations were manufactured, stored in conditions enabling ASR development, and monitored over time. Two expansion levels were selected for analysis (0.08% and 0.15%) and once reached, cores were extracted from three different directions (longitudinal, transverse and vertical) and the DRI conducted on those. Results demonstrate that ASR-induced expansion and deterioration change according to the direction and confinement configuration. Moreover, distinct crack features and orientations are generated in confined concrete, which attests that ASR displays different damage mechanisms under free and confinement conditions.

36 MATERIALS SCIENCE↗

NASA NTRS2001

Detection of Chamber Conditioning Through Optical Emission and Impedance Measurements

During oxide etch processes, buildup of fluorocarbon residues on reactor sidewalls can cause run-to-run drift and will necessitate some time for conditioning and seasoning of the reactor. Though diagnostics can be applied to study and understand these phenomena, many of them are not practical for use in an industrial reactor. For instance, measurements of ion fluxes and energy by mass spectrometry show that the buildup of insulating fluorocarbon films on the reactor surface will cause a shift in both ion energy and current in an argon plasma. However, such a device cannot be easily integrated into a processing system. The shift in ion energy and flux will be accompanied by an increase in the capacitance of the plasma sheath. The shift in sheath capacitance can be easily measured by a common commercially available impedance probe placed on the inductive coil. A buildup of film on the chamber wall is expected to affect the production of fluorocarbon radicals, and thus the presence of such species in the optical emission spectrum of the plasma can be monitored as well. These two techniques are employed on a GEC (Gaseous Electronics Conference) Reference Cell to assess the validity of optical emission and impedance monitoring as a metric of chamber conditioning. These techniques are applied to experimental runs with CHF3 and CHF3/O2/Ar plasmas, with intermediate monitoring of pure argon plasmas as a reference case for chamber conditions.

Cruden, Brett A.↗

NASA NTRS1990

Autonomous planetary rover at Carnegie Mellon

This report describes progress in research on an autonomous robot for planetary exploration. In 1989, the year covered by this report, a six-legged walking robot, the Ambler, was configured, designed, and constructed. This configuration was used to overcome shortcomings exhibited by existing wheeled and walking robot mechanisms. The fundamental advantage of the Ambler is that the actuators for body support are independent of those for propulsion; a subset of the planar joints propel the body, and the vertical actuators support and level the body over terrain. Models of the Ambler's dynamics were developed and the leveling control was studied. An integrated system capable of walking with a single leg over rugged terrain was implemented and tested. A prototype of an Ambler leg is suspended below a carriage that slides along rails. To walk, the system uses a laser scanner to find a clear, flat foothold, positions the leg above the foothold, contacts the terrain with the foot, and applies force enough to advance the carriage along the rails. Walking both forward and backward, the system has traversed hundreds of meters of rugged terrain including obstacles too tall to step over, trenches too deep to step in, closely spaced rocks, and sand hills. In addition, preliminary experiments were conducted with concurrent planning and execution, and a leg recovery planner that generates time and power efficient 3D trajectories using 2D search was developed. A Hero robot was used to demonstrate mobile manipulation. Indoor tasks include collecting cups from the lab floor, retrieving printer output, and recharging when its battery gets low. The robot monitors its environment, and handles exceptional conditions in a robust fashion, using vision to track the appearance and disappearance of cups, onboard sonars to detect imminent collisions, and monitors to detect the battery level.

Whittaker, William↗

NASA NTRS1977

Durability testing at one atmosphere of advanced catalysts and catalyst supports for automotive gas turbine engine combustors, part 1

The durability of catalysts and catalyst supports in a combustion environment was experimentally demonstrated. A test of 1000 hours duration was completed with two catalysts, using diesel fuel and operating at catalytically supported thermal combustion conditions. The performance of the catalysts was determined by monitoring emissions throughout the test, and by examining the physical condition of the catalyst core at the conclusion of the test. The test catalysts proved to be capable of low emissions operation after 1000 hours diesel aging, with no apparent physical degradation of the catalyst support.

Heck, R. M.↗

NASA NTRS1980

Durability testing at 5 atmospheres of advanced catalysts and catalyst supports for gas turbine engine combustors

The durability of CATCOM catalysts and catalyst supports was experimentally demonstrated in a combustion environment under simulated gas turbine engine combustor operating conditions. A test of 1000 hours duration was completed with one catalyst using no. 2 diesel fuel and operating at catalytically-supported thermal combustion conditions. The performance of the catalyst was determined by monitoring emissions throughout the test, and by examining the physical condition of the catalyst core at the conclusion of the test. Tests were performed periodically to determine changes in catalytic activity of the catalyst core. Detailed parametric studies were also run at the beginning and end of the durability test, using no. 2 fuel oil. Initial and final emissions for the 1000 hours test respectively were: unburned hydrocarbons (C3 vppm):0, 146, carbon monoxide (vppm):30, 2420; nitrogen oxides (vppm):5.7, 5.6.

Olson, B. A.↗

DOE OSTI2026

Correlation of Surface Acoustic Wave (SAW) force myography sensor output with elbow joint torque

Accurate assessment of skeletal muscle forces and net joint torque is essential for preventing fatigue-related injuries, optimizing physical training, and monitoring disease progression in neuromuscular conditions. However, existing joint torque evaluation techniques are hindered by limited portability and high operational costs, confining their use to controlled laboratory or clinical settings. Despite substantial advances in wearable joint torque estimation systems, ongoing challenges such as power constraints, bulky wired setups, and susceptibility to environmental or motion artifacts underscore the urgent need for truly batteryless, wireless solutions deployable in real-world settings. This paper proposes a novel surface acoustic wave (SAW)-based force myography (FMG) system for noninvasive measurement of joint torque, validated against a gold-standard electromechanical dynamometer. The approach uses a single SAW sensor embedded in an armband to detect volumetric biceps brachii changes, with a second-order polynomial mapping sensor output and elbow angle to torque. Seven participants were tested in both isometric (15°–90°) and isokinetic (10°/s and 20°/s) supinated elbow flexion tasks. Under isometric conditions, subject-specific calibration achieved a normalized root-mean-square error (NRMSE) of 13.6% ± 6.0% and R 2 = 0.834 ± 0.180, while a group-level model yielded 14.4% ± 6.8% and 0.808 ± 0.208, respectively. For isokinetic trials, the group model produced an NRMSE of 24.1% ± 6.6% at 10°/s and 24.9% ± 08.9% at 20°/s, highlighting the feasibility of using a single-sensor SAW-FMG setup across different speeds. Because SAW devices support wireless, battery-free operation, the proposed system offers a pathway to portable, real-time monitoring for sports medicine, rehabilitation, and clinical diagnostics.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Tonopah Test Range Air Monitoring: CY2020 Meteorological, Radiological, and Wind Transported Particulate Observations

In 1963, the U.S. Department of Energy (DOE) (formerly the Atomic Energy Commission [AEC]), implemented Operation Roller Coaster on the Tonopah Test Range (TTR) and an adjacent area of the Nevada Test and Training Range (NTTR) (formerly the Nellis Air Force Range). This operation resulted in radionuclide-contaminated soils at the Double Tracks site and Clean Slate I, II, and III sites. This report documents observations made during ongoing monitoring of radiological, meteorological, and dust conditions at stations installed adjacent to the Clean Slate sites and at the TTR Sandia National Laboratories (SNL) Range Operations Center (ROC). The monitoring effort supports the DOE Office of Legacy Management in its stewardship of the Clean Slate sites as part of their mission to protect human health and the environment at sites of former nuclear device development and testing. Specific monitoring objectives include determining if wind blowing across the Clean Slate sites is transporting particles of radionuclide-contaminated soil beyond the physical and administrative boundaries of the sites, and providing information for planning long-term stewardship of the sites.

54 ENVIRONMENTAL SCIENCES↗

NASA NTRS1996

Feasibility Study of a Rotorcraft Health and Usage Monitoring System ( HUMS): Usage and Structural Life Monitoring Evaluation

The objective of this study was to evaluate two techniques, Flight Condition Recognition (FCR) and Flight Load Synthesis (FLS), for usage monitoring and assess the potential benefits of extending the retirement intervals of life-limited components, thus reducing the operator's maintenance and replacement costs. Both techniques involve indirect determination of loads using measured flight parameters and subsequent fatigue analysis to calculate the life expended on the life-limited components. To assess the potential benefit of usage monitoring, the two usage techniques were compared to current methods of component retirement. In addition, comparisons were made with direct load measurements to assess the accuracy of the two techniques. The data that was used for the evaluation of the usage monitoring techniques was collected under an independent HUMS Flight trial program, using a commercially available HUMS and data recording system. The usage data collect from the HUMS trial aircraft was analyzed off-line using PC-based software that included the FCR and FLS techniques. In the future, if the technique prove feasible, usage monitoring would be incorporated into the onboard HUMS.

Dickson, B.↗

NASA NTRS1996

Feasibility Study of a Rotorcraft Health and Usage Monitoring System (HUMS): Usage and Structural Life Monitoring Evaluation

The objective of this study was to evaluate two techniques, Flight Condition Recognition (FCR) and Flight Load Synthesis (FIS), for usage monitoring and assess the potential benefits of extending the retirement intervals of life-limited components, thus reducing the operator's maintenance and replacement costs. Both techniques involve indirect determination of loads using measured flight parameters and subsequent fatigue analysis to calculate the life expended on the life-limited components. To assess the potential benefit of usage monitoring, the two usage techniques were compared to current methods of component retirement. In addition, comparisons were made with direct load measurements to assess the accuracy of the two techniques.

Dickson, B.↗