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DOE OSTI2023

Uncertainty quantification in scientific machine learning: Methods, metrics, and comparisons

Neural networks (NNs) are currently changing the computational paradigm on how to combine data with mathematical laws in physics and engineering in a profound way, tackling challenging inverse and ill-posed problems not solvable with traditional methods. However, quantifying errors and uncertainties in NN-based inference is more complicated than in traditional methods. This is because in addition to aleatoric uncertainty associated with noisy data, there is also uncertainty due to limited data, but also due to NN hyperparameters, overparametrization, optimization and sampling errors as well as model misspecification. Although there are some recent works on uncertainty quantification (UQ) in NNs, there is no systematic investigation of suitable methods towards quantifying the total uncertainty effectively and efficiently even for function approximation, and there is even less work on solving partial differential equations and learning operator mappings between infinite-dimensional function spaces using NNs. In this work, we present a comprehensive framework that includes uncertainty modeling, new and existing solution methods, as well as evaluation metrics and post-hoc improvement approaches. Further, to demonstrate the applicability and reliability of our framework, we present an extensive comparative study in which various methods are tested on prototype problems, including problems with mixed input-output data, and stochastic problems in high dimensions. In the Appendix, we include a comprehensive description of all the UQ methods employed. Further, to help facilitate the deployment of UQ in Scientific Machine Learning research and practice, we present and develop in [1] an open-source Python library (github.com/Crunch-UQ4MI/neuraluq), termed NeuralUQ, that is accompanied by an educational tutorial and additional computational experiments.

11 physics-informed neural networks↗

DOE OSTI2025

Updating and Refining BISON TRISO Assessment

Several advanced reactor concepts consider tristructural isotropic (TRISO) fuel in their designs. To support the advanced reactor industry, the Nuclear Energy Advanced Modeling and Simulation (NEAMS) program within the U.S. Department of Energy (DOE) is developing modeling and simulation capabilities within the BISON fuel performance code. Assessment of these capabilities against available experi- mental data, such as the Advanced Gas Reactor (AGR) program, is essential in instilling confidence in the code predictions. Associated uncertainties in model inadequacy, experimental measurements, and manufacturing are also of importance. This report discusses the updating and standardization of the existing assessment suite in BISON for TRISO fuel performance analysis. The cases considered the AGR-1, AGR-2, and AGR-3/4 experimental programs. The report also includes a preliminary investigation into the sources of model inadequacy associated with silver (Ag) release fractions using the AGR-2 Compact 2-1-2 as a case study. The results indicate that uncertainties in the operating temperatures supplied to the model and the form of those temperature conditions (spatially averaged versus spatially resolved) both affect Ag release predictions. This suggests that previously observed model inadequacy can be attributed to both physical models and the operating conditions supplied to them. These findings will be leveraged to guide development of assessment cases for additional experiments and refinement of physical models for behaviors that potentially influence Ag release, such as palladium penetration.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2020

Brief Overview of the NCSP [Slides]

The mission of the NCSP is to provide sustainable expert leadership, direction, and the technical infrastructure necessary to develop, maintain, and disseminate the essential technical tools, training, and data required to support safe, efficient fissionable material operations within the Department of Energy. The vision of the NCSP is a continually improving, adaptable, and transparent program that communicates and collaborates globally to incorporate technology, practices, and programs to be responsive to the essential technical needs of those responsible for developing, implementing, and maintaining nuclear criticality safety.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2021

Aeroacoustic Assessment of Wind Plant Controls

The Aeroacoustic Assessment project aims to quantify changes in aeroacoustic noise generation by a utility scale wind turbine operating under imposed yaw offsets common for wake steering and wind plant control strategies. Active plant control utilizing wake deflection control strategies have been shown experimentally and computationally to reliably produce 1-2% of additional annual energy production (AEP) without significant changes in turbine structural loads, the potential impact on aeroacoustic emissions has yet to be quantified or completely understood. Yawed operation of a wind turbine changes the three-dimensional aerodynamic interaction between the rotor blades and the incoming atmospheric flow, leading to changes in noise generation. This work quantifies the extent to which active control induces additional aeroacoustic emissions from additional separation and other flow interaction dynamic effects. Given public concerns about wind turbine noise and the need for observational data required for regulators to establish noise restrictions, we must understand potential acoustic emissions resulting from active control prior to commercial deployment and the development of practical noise reduction methods and technologies. The work outlined in this report details the new aeroacoustic measurement capability developed at NREL and its application to making full-field observations of noise from a utility-scale wind turbine. Preliminary noise modeling with the aeroacoustics module in OpenFAST helped to establish the design of the experiment, specifically targeting the noise observed at observers distributed around the DOE-owned GE 1.5 MW wind turbine. Low-frequency and infrasound measurement capability implemented in this project establish an operational baseline for the wind turbine, setting the stage for future control, rotor blade, and turbine design research.

17 WIND ENERGY↗

DOE OSTI2024

Deployment and performance of a Low-Energy-Threshold Skipper-CCD inside a nuclear reactor

Charge Coupled Devices (CCD) are being used for reactor neutrino experiments and have already demonstrated their potential in constraining new physics models. The prospect of a Skipper-CCD experiment looking for standard and beyond standard model (BSM) physics in a nuclear reactor has been evaluated for different benchmark scenarios. Here, we report the first installation of a 2-g Skipper-CCD inside the containment building of a 2 GW th nuclear power plant and analyze its performance throughout its first 18 months of operation. The sensor was successfully deployed at Atucha II, in Argentina, 12 meters away from the center of the reactor core. We discuss the challenges involved in the commissioning of the detector and present data acquired during reactor ON and reactor OFF periods, with the sensor functioning with a sub-electron readout noise of 0.17 e - . Based on an exposure of 56.8 g day reactor ON and two reactor OFF data sets with a total exposure of 118.1 g day we characterize the system and evaluate the sensitivity to CEvNS. We achieved a background rate of 33 kdru and a low threshold of 45 eV ee . The ongoing efforts to improve sensitivities to CEvNS and BSM interaction are also discussed.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2023

DRIPS: A framework for dimension reduction and interpolation in parameter space

Reduced-order models are often used to describe the behavior of complex systems, whose simulation with a full model is too expensive, or to extract salient features from the full model’s output. We introduce a new model-reduction framework DRIPS (dimension reduction and interpolation in parameter space) that combines the offline local model reduction with the online parameter interpolation of reduced-order bases (ROBs). The offline step of this framework relies on dynamic mode decomposition (DMD) to build a low-rank linear surrogate model, equipped with a local ROB, for quantities of interest derived from the training data generated by repeatedly solving the (nonlinear) high-fidelity model for multiple parameter points. The online step consists of the construction of a parametric reduced-order model for each target/test point in the parameter space, with the interpolation of ROBs done on a Grassman manifold and the interpolation of reduced-order operators done on a matrix manifold. The DMD component enables DRIPS to model (typically low-dimensional) quantities of interest directly, without having to access the (typically high-dimensional and possibly nonlinear) operators in a high-fidelity model that governs the dynamics of the underlying high-dimensional state variables, as required in projection-based reduced-order modeling. A series of numerical experiments suggests that DRIPS yields a model reduction, which is computationally more efficient than the commonly used projection-based proper orthogonal decomposition; it does so without requiring a prior knowledge of the governing equation for quantities of interest. Furthermore, for the nonlinear systems considered, DRIPS is more accurate than Gaussian-process interpolation (Kriging).

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2020

Real Time Data Analysis With the ATLAS Trigger at the LHC in Run-2

The trigger selection capabilities of the ATLAS detector have been significantly enhanced for the LHC Run- 2 in order to cope with the higher event rates and with the large number of simultaneous interactions (pile-up) per protonproton bunch crossing. A new hardware system, designed to analyse real time event-topologies at Level-1 came to full use in 2017. A hardware-based track reconstruction system, expected to be used real-time in 2018, is designed to provide track information to the high-level software trigger at its full input rate. The high-level trigger selections are largely relying on offline-like reconstruction techniques, and in some cases multivariate analysis methods. Despite the sudden change in LHC operations during the second half of 2017, which caused an increase in pile-up and therefore also in CPU usage of the trigger algorithms, the set of triggers (so called trigger menu) running online has undergone only minor modifications thanks to the robustness and redundancy of the trigger system, and the use of a levelling luminosity scheme in agreement with LHC and other experiments. Here, this presentation gives a brief yet comprehensive review of the real-time performance of the ATLAS trigger system in 2017. Considerations will be presented on the most relevant parameters of the trigger (efficiency to collect signal and output data rate) as well as details on some aspects of the algorithms which are run real-time on the High Level Trigger CPU farm.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2025

Machine learning for single-ended event reconstruction in PROSPECT experiment

The Precision Reactor Oscillation and Spectrum Experiment, PROSPECT, was a segmented antineutrino detector that successfully operated at the High Flux Isotope Reactor in Oak Ridge, TN, during its 2018 run. Despite challenges with photomultiplier tube base failures affecting some segments, innovative machine learning approaches were employed to perform position and energy reconstruction, and particle classification. This work highlights the effectiveness of convolutional neural networks and graph convolutional networks in enhancing data analysis. By leveraging these techniques, a 3.3% increase in effective statistics was achieved compared to traditional methods, showcasing their potential to improve analysis performance. Furthermore, these machine learning methodologies offer promising applications for other segmented particle detectors, underscoring their versatility and impact.

47 OTHER INSTRUMENTATION↗

DOE OSTI2022

Deciphering Nb 98 β decay with the Modular Total Absorption Spectrometer at ORNL

An assessment done under the auspices of the Organization for Economic Co-operation and Developement Nuclear Energy Agency (OECD-NEA) in 2007 suggested that the β decays of many abundantly produced fission products in nuclear reactors may be incomplete. In this assessment, the fission product 98 Nb was assigned the highest priority for study by total absorption spectroscopy due to its large cumulative fission branching fraction and because the β-decay data from several experiments are discrepant. To obtain the complete β-decay feeding pattern of 98 Nb and determine the impact on the average γ energy per 98 Nb β decay and v¯e emission calculations. The complete 98 Nb β-decay feeding pattern includes ground-state to ground-state β feeding and direct β feeding to the 0 + first-excited state (both have no associated γ rays), and the ground-state to excited-state β transitions followed by γ transitions to the ground state of the daughter nucleus, 98 Mo. The complete β-decay intensities of 98 Nb were measured with the Modular Total Absorption Spectrometer at Oak Ridge National Laboratory (ORNL). Here, the 98 Nb was produced by the β decay of mass 98 fission fragments at ORNL's On-Line Test Facility (OLTF) using proton-induced fission of 238 U. We find that changes to the current ENSDF assessment of 98 Nb β-decay intensity are required. We report improved uncertainties for the β-decay feeding values and report new β feedings to high-energy levels in 98 Mo. A more complete 98 Nb β-feeding pattern with improved accuracy and precision is offered. The impacts of the measured changes to the 98 Nb β-feeding pattern on both reactor decay heat calculations and predicted detection rates of reactor v¯e are presented. The Modular Total Absorption Spectrometer measurements of 98 Nb demonstrate the importance of reexamining and remeasuring complex β-decaying fission products with total absorption spectroscopy, including nuclei very near β stability.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2024

Hardware-in-the-Loop Testing of Wide-Area Damping Controller for Field Implementation in Large-scale Power Grid

In our previous work, an adaptive measurement-driven wide-area damping controller (WADC) for suppressing inter-area oscillations has been proposed and a hardware prototype was developed and validated through hardware-in-the-loop tests. As a continuation of the work, this paper introduces a WADC software prototype to handle the realistic challenges for field implementation in the control room of the power grid. The WADC software is developed and operated as an openPDC adapter with a graphical user interface (GUI) to monitor the WADC inputs and output, the communication delays and other variables. The software prototype has been fully tested through an enhanced hardware-in-the-loop (HIL) test setup. Its performance is verified under various realistic communication uncertainties, such as random time delays and data losses, with different communication protocols. The experiment results have proven the WADC software can deliver sufficient damping to suppress the targeted oscillation mode in handling various communication uncertainties for future field deployment.

Jia, Xinlan↗

DOE OSTI2023

Digital holography for real-time non-invasive monitoring of larval fish at power plant intakes

Effective evaluation of technological and operational approaches to reduce entrainment of marine organisms at cooling water intake structures (CWIS) requires accurate organism-sensing systems. Current detection methods lead to large temporal data gaps, require tedious manual analysis, and are fatal to organisms. In this report we describe integrating deep learning with a non-lethal, non-intrusive imaging method—digital holography—to rapidly detect fish larvae. Laboratory experiments demonstrated that the instrument could successfully image fish larvae at flow rates exceeding ranges seen in CWIS. Holograms of two fish larvae species, in the presence of bubbles and detritus, were collected to build a large database for training a lightweight convolutional neural network. The model achieves 97% extraction accuracy in quantifying larvae, and distinguishing them from other particles, including detritus and bubbles, when applied to a dataset of manually classified images, exceeding previous metrics for non-lethal, accurate, and real-time detection. These results demonstrate the potential of in situ holographic imaging for monitoring endangered larval fish species at power plant intake structures, and for high-fidelity, real-time applications in monitoring aquatic ichthyoplankton.

endangered species↗

DOE OSTI2020

Initial Efforts Organizing WPNCS SG-8: Preservation of Expert Knowledge and Judgement Applied to Criticality Benchmarks

The Working Party on Nuclear Criticality Safety (WPNCS) under the guidance of the Organization for Economic Co-operation and Development (OECD) Nuclear Energy Agency (NEA) has over 20 years of experience addressing concerns related to static and transient configurations encountered within the nuclear fuel cycle: fuel fabrication, transportation, reprocessing, storage, and geological disposal. One of the cornerstone activities of the WPNCS is the International Criticality Safety Benchmark Evaluation Project (ICSBEP), which was established to identify a comprehensive set of criticality benchmark data, evaluate the data, including quantification of overall uncertainties; compile the data into a standardized format, perform sample calculations utilizing modern nuclear data sets and codes utilized in nuclear criticality safety, and formally document the work into a single source of verified benchmark data. Annually, members of the ICSBEP Technical Review Group (TRG) contribute evaluated benchmark data that undergoes comprehensive technical review prior to publication in the ICSBEP Handbook. In the years since the ICSBEP was established, there has been much work to prepare benchmark data to support validation activities in nuclear criticality safety. The 2020 edition of the ICSBEP Handbook contains acceptable benchmark specifications for 5,053 critical, subcritical, or near-critical configurations in 582 benchmark evaluations. Modern benchmark development benefits from decades of experienced international participants, a well-established handbook format, supplementary guides to deal with uncertainty quantification, and a comprehensive review process based upon independent reviews from international experts. The ICSBEP Handbook also contains 838 configurations deemed unacceptable to support criticality safety efforts. They are recorded, with the reasoning for their rejection, to preserve the experimental data, prevent reevaluation of data that are incomplete or contain known errors, and/or to potentially allow future reevaluation of the experiment pending the identification of sufficient data to resolve identified inconsistencies and errors. Users of the ICSBEP Handbook today might notice that the rigor and quality of modern criticality safety benchmarks is much greater than those prepared within the initial decade of the project. Benchmarks with 1s uncertainties in k eff greater than 1% were traditionally rejected unless they were identified as unique experiment types that encompassed materials, fuels, or designs not available from other benchmark experiments. However, benchmarks developed using modern experimental techniques and practices typically have uncertainties on the order of a few tenths of a percent. There have been ongoing efforts to improve the overall quality of previously published benchmark evaluations. Seventy-eight evaluations, containing approximately 600 configurations, have been revised just within the past decade. An additional eleven benchmarks are under revision for updated release in the 2020 edition of the ICSBEP Handbook. If some of the historic benchmarks were resubmitted in their current form to the TRG today, they would be rejected due to lack of data, missing components in the uncertainty analysis, or incomplete benchmark model development. The use of historic criticality safety benchmarks that underestimate the total uncertainty, lack properly quantified biases, or provide inadequate benchmark specifications do not sufficiently support modern criticality safety and nuclear data efforts. Although the ICSBEP Handbook is recognized by regulating bodies to support criticality safety, users are required to justify their reasons to ignore historic benchmark data and include additional safety margins within their designs. Discussions were held at the WPNCS 23rd Annual Meeting in September 2019 regarding the aforementioned issues. The resultant decision was to establish Subgroup 8 (SG-8): Preservation of Expert Knowledge and Judgement Applied to Criticality Benchmarks. The current activities of SG-8 are discussed herein.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2023

ULTIMATE FY22 Creep Test Facility Report (FY23 ARPA-E Milestone Report)

In the 18-month Phase 1 of this project, a facility was assembled for creep testing of refractory metals at 1300°C. This report focuses on the four creep frames that are operational and using an inert gas system (argon) to limit oxidation of the refractory metal specimens being tested. This report details the operations for the first period of operation including the results and lessons learned for Nb- and Mo-based alloy specimens tested by the ORNL team. For an alloy development program, a particularly unique feature of the ORNL facility is more than 40 years of experience conducting mechanical properties testing on sub-sized test specimens (25 mm long dogbones). Due to proprietary constraints, only one representative set of team data are provided. The primary concern for testing Nb-based alloys is oxygen ingress. Despite several strategies to reliably limit O ingress, including getters and Ar gas purity, the experimentally informed strategy currently being developed is a new load train design intended to better seal the system. Hardware for the new design is currently being fabricated.

36 MATERIALS SCIENCE↗

DOE OSTI2024

ARM Aerial Facility (AAF) Merged Value-Added Product Report for Historical G-1 Field Campaigns

For 30 years, the U.S. Department of Energy (DOE) Office of Science supported an instrumented Grumman Gulfstream-1 (G-1) aircraft for atmospheric field campaigns. Data from the final decade of G-1 operations were archived by the Atmospheric Radiation Measurement (ARM) user facility Data Center (ADC) and made publicly available at no cost to all registered users. To ensure a consistent data format and to improve the accessibility of the ARM airborne data, an integrated data set was recently developed covering the final six years of G-1 operations (2013 to 2018). The integrated data set includes data collected from 236 flights (766.4 hours). Four of the seven field campaigns were based in the U.S. One campaign collected data from the wildfires in the U.S. Pacific Northwest and agricultural burns in the lower Mississippi River valley as part of the Biomass Burning Observation Project (BBOP) in 2013. In 2015, the ARM Cloud Aerosol Precipitation Experiment provided data on atmospheric rivers and associated aerosol-cloud interactions that produce heavy precipitation on the U.S. west coast during the early spring. Research data from Airborne Carbon Measurements-V (ACME-V), collected during the summer of 2015, gave scientists insight into trends and variability of trace gases in the atmosphere over the North Slope of Alaska to improve arctic climate models. In the early summer and autumn of 2016, the Holistic Interactions of Shallow Clouds, Aerosols, and Land-Ecosystems (HI-SCALE) campaign provided an extensive data set geared toward coupled processes that affect the life cycle of shallow clouds through the interaction among aerosol, cloud, land surface, and ecosystems. In 2014 (March and October), the airborne sampling moved outside of the U.S. to the city of Manaus in central Amazonia, Brazil, where residential and industrial emissions were extensively characterized by flights of the G-1. The GoAmazon2014/15 aircraft campaign data are being integrated with aquatic and terrestrial ecosystem measurements to quantify anthropogenic perturbations to a usually pristine tropical environment. Another international airborne mission was carried out in the Eastern North Atlantic region. The Aerosol and Cloud Experiments in the Eastern North Atlantic (ACE-ENA) campaign saw the G-1 aircraft fly from Terceira Island in the Azores during the summer of 2017 and the winter of 2018. The campaign studied both seasons to measure key aerosol and cloud processes under various meteorological and cloud conditions with different aerosol sources. Then the G-1 deployed to the Sierras de Córdoba range in central Argentina from October to November 2018 for the Cloud, Aerosol, and Complex Terrain Interactions (CACTI) campaign to study orographic convective cloud interactions with their surrounding environment. These comprehensive datastreams provide much-needed insight into spatiotemporal variability of thermodynamic quantities, aerosol and cloud states, and properties for addressing essential science questions in Earth system process studies.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2024

ARM Aerial Facility (AAF) Merged Value-Added Product Report for Historical G-1 Field Campaigns

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2026

Toward Trustworthy Detectors Detector Characterization for SuperCDMS SNOLAB Commissioning

SuperCDMS SNOLAB is a next generation direct detection experiment searching for low mass dark matter using cryogenic germanium and silicon detectors operated at millikelvin temperatures. As commissioning begins, establishing stable, predictable detector response to energy deposits is a prerequisite for future physics analysis. This work studies detector stability and calibration for four SuperCDMS SNOLAB detectors, det 7 and det 15 (germanium) and det 11 and det 14 (silicon), using Barium-133 calibration data (356 keV gamma ray reference) and low background data (ambient radiation, no external source). The Ba-133 data show no distinct line at the expected energy, and the low background data show a baseline that drifts and oscillates rather than remaining flat, consistently across multiple channels, suggesting a shared, detector wide cause. These observations point to the cryogenic support system as the likely source, since small temperature fluctuations could couple into the temperature sensitive detectors, informing the ongoing commissioning effort.

O'Hanlon, Vika [Skidmore Coll.]↗

DOE OSTI2024

An assessment of ocean alkalinity enhancement using aqueous hydroxides: kinetics, efficiency, and precipitation thresholds

Abstract. Ocean alkalinity enhancement (OAE) is a promising approach to marine carbon dioxide removal (mCDR) that leverages the large surface area and carbon storage capacity of the oceans to sequester atmospheric CO2 as dissolved bicarbonate (HCO3-). One OAE method involves the conversion of salt in seawater into aqueous alkalinity (NaOH), which is returned to the ocean. The resulting increase in seawater pH and alkalinity causes a shift in dissolved inorganic carbon (DIC) speciation toward carbonate and a decrease in the surface ocean pCO2. The shift in the pCO2 results in enhanced uptake of atmospheric CO2 by the seawater due to gas exchange. In this study, we systematically test the efficiency of CO2 uptake in seawater treated with NaOH at aquarium (15 L) and tank (6000 L) scales to establish operational boundaries for safety and efficiency in advance of scaling up to field experiments. CO2 equilibration occurred on the order of weeks to months, depending on circulation, air forcing, and air bubbling conditions within the test tanks. An increase of ∼0.7–0.9 mol DIC per mol added alkalinity (in the form of NaOH) was observed through analysis of seawater bottle samples and pH sensor data, consistent with the value expected given the values of the carbonate system equilibrium calculations for the range of salinities and temperatures tested. Mineral precipitation occurred when the bulk seawater pH exceeded 10.0 and Ωaragonite exceeded 30.0. This precipitation was dominated by Mg(OH)2 over hours to 1 d before shifting to CaCO3,aragonite precipitation. These data, combined with models of the dilution and advection of alkaline plumes, will allow the estimation of the amount of carbon dioxide removal expected from OAE pilot studies. Future experiments should better approximate field conditions including sediment interactions, biological activity, ocean circulation, air–sea gas exchange rates, and mixing zone dynamics.

Ringham, Mallory C. (ORCID:0000000348020185)↗

DOE OSTI2021

Development of NDE/NDT Tools for High-Volume & High-Speed Inspection of CFRP Structures in Automotive Manufacturing

Main advantages of the air-coupled ultrasound testing (ACUT) and electromagnetic testing (EMT) techniques for NDE of CFRP composites were non-contact sensing, scalability for high-speed inspection, cost-effectiveness, and non-hazardous operation. Despite these advantages, no systems that would satisfy the project requirements were commercially available. Hence, one of the major efforts of the Michigan State University (MSU) team at the initial stage of the project was to close this technological gap by developing, optimizing, and validating array sensors that would provide sufficient sensitivity, spatial coverage, and resolution for robust defect detection. Optimization of the ACUT and EMT sensor designs was performed using experimentally validated finite element models. Initial experiments using array probes were conducted on relatively flat CFRP samples. In parallel, the MSU team designed and assembled a portable platform with two robotic arms. The robots were equipped with newly designed sensors that enabled high-speed NDE of curved CFRP parts. Presently, the developed robotic platform can be used as a demo/template NDE system, which is easily adaptable to manufacturing environments and in-line NDE. The ACUT NDE system developed by the MSU team used a high-power 4-channel pulser receiver for parallel data acquisition. The array probes were designed by stacking commercially available ACUT transducers, which operated in the frequency range between 100 kHz and 500 kHz. MSU optimized the excitation procedure and developed wave focusing cones so as to reduce the crosstalk between the transducers and to provide higher pulse repletion frequency (PRF). The through-transmission (TT) and single-side access (SSA) inspection modes were successfully implemented. In the TT-ACUT, structural defects in CFRP were detected by passing ultrasonic waves through the test part. Hence, the ACUT transmitters and receivers needed to be placed on the opposite sides of the test part. In the SSA-ACUT, guided waves (GW) were excited in the test part using the transmitters and were sensed by the receivers from the same side. Multi-channel TT-ACUT and SSA-ACUT provided high-speed NDE, and were successfully validated on CFRP test samples with interlaminar delaminations and other embedded defects The EM techniques developed by the MSU team included: 1) eddy current testing (ECT), 2) capacitive imaging (CI) and hybrid dual-mode imaging. In ECT, structural damage was detected in CFRP using coils sensor arrays. In ECT, the excitation magnetic field is generated by passing an alternating current through a coil, which is placed above the test sample. The excitation field penetrates the conductive sample and induces the eddy currents in its transect. In turn, the eddy currents generate the reaction field, which affects the total field sensed by a coil. Hence, the presence of structural flaws will alter the eddy current flow and the picked-up signal. ECT is mostly sensitive to local changes of the electric conductivity of the test sample, and CFRPs are mostly conductive in the direction of carbon fibers. Hence, ECT was well suited for the detection of fiber damage/fiber irregularities. The MSU team developed printed circuit boards (PCB) with coil sensor arrays optimized for NDE of CFRP. Unlike most commercial probes designed for ECT of metallic structures, the MSU array probes were designed for operation in [1-10] MHz frequency range, which was optimal for low-conductive CFRP. Multiple sensing topologies (coil groups excitation/sensing arrangements) were implemented and successfully validated. Capacitive Imaging (CI) technique developed by MSU was complementary to ECT. In contrast to ECT, which was sensitive to local changes of the electrical conductivity, the CI was sensitive to local changes of the dielectric constant. Therefore, CI could provide information about matrix damage/matrix irregularities in CFRP. The MSU CI sensor arrays were made of multiple circular or rectangular open-plate capacitors printed on PCB. Sensors of this type are not commercially available. In addition to ECT and CI, the MSU team developed a hybrid (dual-mode) inductive/capacitive measurement technique that synergistically combined the benefits of inductive and capacitive sensing for rapid NDE of fiber reinforced polymer (FRP) composite structures. Fiber damage and fiber irregularities in FRPs were detected by configuring hybrid sensors as coil sensors. Similarly, matrix damage, matrix irregularities and interlaminar delaminations were detected by configuring hybrid sensors as capacitive sensors. ECT and CI were performed sequentially by means of electronic switching. Hence, eliminating the need for mounting two separate sensor arrays on the probe. Portable robotic platform was developed by MSU for multi-technique high-speed NDE of CFRP test parts. The platform had two 6-axis robots, which enabled inspection of curved parts in approximately a 6×6×6 ft 3 active scan area. On the software side, the MSU team integrated scripts for NDE hardware control with scripts for robot motion control. MSU also implemented automated path planning for the robots, reconstruction of part’s surfaces via stereovision, 3D rendering of inspection data, and image processing algorithms for enhanced defect detection. Automotive composite parts manufactured by Plasan Composites from Phase I were used to validate the ACUT and EMT techniques on representative testbeds. Among those parts were three X-braces for a Dodge Viper, one composite calibration plaque with known defects at known locations, and four other test sections, including sections from a front splitter, a corner section from a composite hood, and a high-pressure RTM panel made using non crimp fabric. Other test samples included CFRP and GFRP calibration plates with fiber/matrix defects fabricated at MSU/CVRC.

36 MATERIALS SCIENCE↗