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All sources NASA NTRS DOE OSTI

DOE OSTI2022

Multi phenomena melt pool sensor data fusion for enhanced process monitoring of laser powder bed fusion additive manufacturing

Finding actionable trends in laser-based metal additive manufacturing process monitoring data is challenging owing to the diversity and complexity of the underlying physical interactions. A single monitoring solution that captures a particular process phenomenon, such as a photodiode that tracks melt pool intensity, is not alone capable of evaluating process stability or detecting flaw formation with sufficient precision for routine application in industry. In this work, to improve flaw detection performance, we adopted a data fusion approach that captures multiple process phenomena. To demonstrate this, we acquired data from laser powder bed fusion (LPBF) builds of cylindrical specimens produced with different laser spot sizes, emulating defocusing due to process faults such as thermal lensing. The resulting specimens had porosity of varying types and severity, quantified by post-build non-destructive X-ray computed tomography, Archimedes density measurements, and destructive metallographic characterization. During the build, the melt pool state was monitored with two coaxial high-speed video cameras and a temperature field imaging system. Physically intuitive low-level melt pool signatures, such as melt pool temperature, shape and size, and spatter intensity were extracted from this high-dimensional, image-based sensor data. These process signatures were subsequently used as input features in relatively simple machine learning models, such as a support vector machine, which were trained to detect laser defocusing, and in addition, predict porosity type and severity. The results show that the data fusion approach significantly enhanced system performance by reducing the overall false positive rate from ~ 0.1 to ~ 0.001 without sacrificing the true positive rate (~0.90). These results were at par with a black-box, deep machine learning approach (convolutional neural network).

36 MATERIALS SCIENCE↗

DOE OSTI2023

Use of Sensors and Machine Learning for Signal Discovery in a Solvent Extraction Process

Reprocessing is an important step in the nuclear fuel cycle where usable nuclear materials are extracted from used fuel for recycling. The separation of materials for reuse simultaneously reduces not only the volume of nuclear waste, but its decay time to radioactivity levels similar to that of the originating uranium ore. As part of an initiative to steward research, development, and innovation into the nuclear fuel cycle, Idaho National Laboratory is designing and constructing a solvent extraction testbed named Beartooth. This testbed will allow researchers to refine separation processes, test innovative extraction processes, and give early career scientists opportunities to gain skills in performing separations chemistry utilizing centrifugal contactors. In addition, the Beartooth testbed is being uniquely designed to enable novel technologies including machine learning capabilities for the characterization of chemical process operations in near real-time. To aid in the design of Beartooth, a team of researchers are installing a variety of atypical sensors into a system of contactors for signal discovery. The team will implement machine learning methods on acquired sensor data to extract signal features. The goal is to provide a process operator with a deeper understanding of the chemical process and equipment usage. This work will summarize sensors utilized and preliminary results from an infrared camera.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

Nucleation and Growth of Blue Phase 3D Cubic Structure Under Continuously Changing Curved Boundary Conditions

The blue phase of liquid crystals (BPLCs) with a cubic lattice of disclination lines and 3D nanostructure enables the modulation of photonic bandgap thus casting them in the category of photonic crystals. Its unique nature promises applications in display technologies, electro‐optics, and sensors. To integrate these ordered materials into wearable devices a fundamental understanding of curvature, and spatial confinement is necessary. Although continuous confinement in flat geometries have been studied, confining curvature has shown to induce strong destabilization effects on the cubic structure and formation of topological defects, thereby deteriorating their optical performance. Moreover, limitations in controlling the curvature of droplets further hinder studies of nucleation and growth of BPLCs. Here, to address these challenges, micro‐scale patterned surfaces of concentric cylinders are exploited to systematically control curvatures. The impact of curvature on the confined BPLCs is revealed in terms of phase transition temperature, nucleation and growth, morphology, as well as phase transformation. This research offers valuable insights into the stability, and structural characteristics of BPLCs in adaptive photonic devices, paving the way for future advancements in flexible displays, sensors, and other technologies leveraging liquid crystal (LC) materials.

3D Cubic Structure↗

DOE OSTI2019

Embedded Optical Sensing Systems For Distribution Transformer Monitoring

Traditional utility monitoring systems do not provide real-time visibility into the condition of transformers or accurate performance measurements. This has resulted in the use of lagging indicators, such as oil sample analysis, typically requiring expensive field visits, grid outages, and laboratory sample testing. This presentation reviews the use of optical sensing systems for managing transformers and improving grid resiliency and safety. The sensing systems allow direct internal monitoring of critical transformer components. Versatility covering different monitoring parameters of interest in embedded configurations for new transformers and a retrofittable configuration for older transformers is achieved by applying hair-thin multiplexed fiber-optic and other low-profile optical sensors in combination with a high-resolution optical readout and advanced analytics. Under an initiative funded by the DOE Office of Electricity, PARC, GE and Con Edison built, tested, and qualified commercial network transformers with embedded optical sensing systems. The parameters monitored were validated across a range of scenarios with lab instruments typically used for qualification testing. An ongoing field trial to demonstrate the robustness of the technology for remote monitoring through the industrial internet under demanding grid deployment conditions in New York City is showing promise toward scale-up of the technology. This presentation will provide an overview of the typical pain points in managing transformers and parameters for monitoring. It will also cover the requirements for highly constrained installations that need to have a larger capacity and flexible rating but that must fit into a tight space. The unique capabilities of optical sensing systems and a low-cost approach to interpreting the signals from sensors in transformers for predictive maintenance will be covered. The presentation will discuss the compatibility of the sensors in the transformer environment. It will discuss the validation testing per IEEE standards that enabled the solution to be implemented in field-deployable commercial transformers. The initial results from the field deployment and the potential for the technology to provide systematic alerts for unsafe/unexpected events will be discussed. The technology could enable utility professionals to gain information they can use to better plan for maintenance/management, and improve grid performance. This would in turn accommodate DERs and other evolving grid market dynamics.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2023

Use of Sensors and Machine Learning for Signal Discovery in a Solvent Extraction Process – 23280

Reprocessing is an important step in the nuclear fuel cycle where usable nuclear materials are extracted from spent fuel for recycling. The extraction of materials for reuse simultaneously reduces not only the volume of nuclear waste, but its decay time to radioactivity levels similar to that of the originating uranium ore. As part of an initiative to steward research, development, and innovation into the nuclear fuel cycle, Idaho National Laboratory is designing and constructing a solvent extraction testbed named Beartooth. Beartooth will allow researchers to refine extraction processes, test innovative extraction processes, and give early career scientists opportunities to gain skills in performing separations chemistry that uses centrifugal contactors. In addition, the Beartooth testbed is being uniquely designed to enable novel technologies including machine learning capabilities for the characterization of chemical process operations in near real-time. To aid in the design of Beartooth, a team of researchers are installing a variety of atypical sensors into a system of contactors for signal discovery. The team will implement machine learning methods on sensor data to determine signal features with the goal of providing a process operator with a deeper understanding of the chemical process and equipment usage. This work will summarize sensors utilized and preliminary results from an infrared camera.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2019

Microwave Multiplexing on the Keck Array

In this paper, we describe an on-sky demonstration of a microwave-multiplexing readout system in one of the receivers of the Keck Array, a polarimetry experiment observing the cosmic microwave background at the South Pole. During the austral summer of 2018–2019, we replaced the time-division multiplexing readout system with microwave-multiplexing components including superconducting microwave resonators coupled to radio frequency superconducting quantum interference devices at the sub-Kelvin focal plane, coaxial-cable plumbing and amplification between room temperature and the cold stages, and a SLAC Microresonator Radio Frequency system for the warm electronics. In the range 5–6 GHz, a single coaxial cable reads out 528 channels. The readout system is coupled to transition-edge sensors, which are in turn coupled to 150-GHz slot-dipole phased-array antennas. Observations began in April 2019, and we report here on an initial characterization of the system performance.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2023

Particle showers detected on ISS in Timepix pixel detectors

We detect regular particle showers in several compact pixel detectors, distributed over the International Space Station. These showers are caused by high energy galactic cosmic rays, with energies often in the 10 s of TeV or higher. We survey the frequency of these events, their dependence on location on ISS, and their independence of the location of ISS, on its orbit. The Timepix detectors used allow individual particle tracks to be resolved, providing a possibility to perform physical analysis of shower events, which we demonstrate. In terms of radiation dosimetry, these showers indicate certain possible limitations of traditional dosimetric measures, in that (a) the dose measured in small sensor may be less than that received in a larger distribution of matter, such as a human and (b) the spatial and temporal extent of these events represents a regime of poorly documented biological response.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2026

Silicon pinhole strip defects and their impact on ATLAS Inner Tracker HV current measurement

In preparation for the High-Luminsity LHC (HL-LHC) [1], the ATLAS detector will undergo major detector upgrades, including the replacement of the current Inner Detector with the new all-silicon Inner Tracker (ITk) [2]. The ITk consists of a pixel detector close to the beamline surrounded by a large-area strip detector. During detector production, the electrical properties of silicon sensors and readout electronics must be characterized through a series of quality control (QC) and quality assurance tests. These tests ensure any defect is captured at the earliest possible stage. One such defect, callled a pinhole, occurs when the strip implant and the metal readout electrode are shorted through the intermediary dielectric layer. Notably, the introduction of pinholes during module assembly and pinhole effects on completed modules, especially on leakage current measurement circuitry, have never been studied. In this paper, we investigate the effect of such connections on the sensor leakage current measurements of completed modules and introduce new ways to locate pinholed strips. Here, with minor modifications to testing procedures, such defects are shown not to impede module testing or performance.

FOS: Physical sciences↗

DOE OSTI2023

Cost Benefit Analyses through Integrated Online Monitoring and Diagnostics (Final Report)

The objective of this research is to improve the economic competitiveness of advanced reactors through the optimization of cost and plant performance, which can be achieved by coupling intelligent online monitoring with asset management decision-making. As advanced reactors are early in the development life-cycle, online monitoring systems and associated sensor networks can be incorporated directly into the design without constraints related to retrofitting and system upgrades

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2025

A Predictive Model for Internal Magazine Temperatures

This report describes data and methodology used to predict temperatures inside magazines used to store explosive devices, based on outside temperatures from a local weather station and data logged by sensors inside a single magazine over a limited period. It follows on earlier work and predictive models. In conjunction with aging models, predicted temperatures can be used to estimate degradation in the performance of explosives over long periods of storage.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗

DOE OSTI2021

An Algebra of Machine Learners with Applications

Machine learning (ML) methods are increasingly being applied to solve complex, data-driven problems in diverse areas, by exploiting the physical laws derived from first principles such as thermal hydraulics and the abstract laws developed recently for data and computing infrastructures. These physical and abstract laws encapsulate, typically in compact algebraic forms, the critical knowledge that complements data-driven ML models. We present a unified perspective of these laws and ML methods using an abstract algebra (A;⊕,Ⓧ), wherein the performance estimation and classification tasks are characterized by the additive ⊕ operations, and the diagnosis, reconstruction, and optimization tasks are characterized by the difference Ⓧ operations. This abstraction provides ML codes and their performance characterizations that are transferable across different areas. We describe practical applications of these abstract operations using examples of throughput profile estimation tasks in data transport infrastructures, and power-level and sensor error estimation tasks in nuclear reactor systems.

Rao, Nageswara↗

DOE OSTI2021

Hardware-Based Emulator with Deep Learning Model for Building Energy Control and Prediction Based on Occupancy Sensors’ Data

Heating, ventilation, and air conditioning (HVAC) is the largest source of residential energy consumption. Occupancy sensors’ data can be used for HVAC control since it indicates the number of people in the building. HVAC and sensors form a typical cyber-physical system (CPS). In this paper, we aim to build a hardware-based emulation platform to study the occupancy data’s features, which can be further extracted by using machine learning models. In particular, we propose two hardware-based emulators to investigate the use of wired/wireless communication interfaces for occupancy sensor-based building CPS control, and the use of deep learning to predict the building energy consumption with the sensor data. We hypothesize is that the building energy consumption may be predicted by using the occupancy data collected by the sensors, and question what type of prediction model should be used to accurately predict the energy load. Another hypothesis is that an in-lab hardware/software platform could be built to emulate the occupancy sensing process. The machine learning algorithms can then be used to analyze the energy load based on the sensing data. To test the emulator, the occupancy data from the sensors is used to predict energy consumption. The synchronization scheme between sensors and the HVAC server will be discussed. We have built two hardware/software emulation platforms to investigate the sensor/HVAC integration strategies, and used an enhanced deep learning model—which has sequence-to-sequence long short-term memory (Seq2Seq LSTM)—with an attention model to predict the building energy consumption with the preservation of the intrinsic patterns. Because the long-range temporal dependencies are captured, the Seq2Seq models may provide a higher accuracy by using LSTM architectures with encoder and decoder. Meanwhile, LSTMs can capture the temporal and spatial patterns of time series data. The attention model can highlight the most relevant input information in the energy prediction by allocating the attention weights. The communication overhead between the sensors and the HVAC control server can also be alleviated via the attention mechanism, which can automatically ignore the irrelevant information and amplify the relevant information during CNN training. Our experiments and performance analysis show that, compared with the traditional LSTM neural network, the performance of the proposed method has a 30% higher prediction accuracy.

Ye, Zhijing↗

DOE OSTI2024

Digital twin advanced distribution management systems (ADMS) and methods

Advanced Distribution Management Systems not generally optimize over the entire feeder because there are few high-fidelity distribution circuit models and real-time distribution-connected sensors are rare. The limited observability at the distribution level makes it difficult to globally optimize distribution operations and issue control setpoints to power systems equipment or Distributed Energy Resources (DER) to perform grid-support services. For example, setpoints can be issued to DER based on results from an optimization module that incorporates a static or time-series feeder simulation. Feeder simulation initial conditions are populated with photovoltaic (PV) and load forecasts, state estimation results, and/or digital twin measurements or state output. The real-time (RT) digital twin runs a model of the feeder to generate state estimation pseudo-measurements since there are limited live feeder measurements.

Johnson, Jay Tillay↗

DOE OSTI2025

Temporal Forecasting of Distributed Temperature Sensing in a Thermal Hydraulic System With Machine Learning and Statistical Models

We benchmark performance of long-short term memory (LSTM) network machine learning model and autoregressive integrated moving average (ARIMA) statistical model in temporal forecasting of distributed temperature sensing (DTS). Data in this study consists of fluid temperature transient measured with two co-located Rayleigh scattering fiber optic sensors (FOS) in a forced convection mixing zone of a thermal tee. We treat each gauge of a FOS as an independent temperature sensor. We first study prediction of DTS time series using Vanilla LSTM and ARIMA models trained on prior history of the same FOS that is used for testing. The results yield maximum absolute percentage error (MaxAPE) and root mean squared percentage error (RMSPE) of 1.58% and 0.06% for ARIMA, and 3.14% and 0.44% for LSTM, respectively. Next, we investigate zero-shot forecasting (ZSF) with LSTM and ARIMA trained on history of the co-located FOS only, which is advantageous when limited training data is available. The ZSF MaxAPE and RMSPE values for ARIMA are comparable to those of the Vanilla use case, while the error values for LSTM increase. We show that in ZSF, performance of LSTM network can be improved by training on most correlated gauges between the two FOS, which are identified by calculating the Pearson correlation coefficient. The improved ZSF MaxAPE and RMSPE for LSTM are 4.4% and 0.33%, respectively. Performance of ZSF LSTM can be further enhanced through transfer learning (TL), where LSTM is re-trained on a subset of the FOS that is the target of forecasting. We show that LSTM pre-trained on correlated dataset and re-trained on 30% of testing target dataset achieves MaxAPE and RMSPE values of 2.32% and 0.28%, respectively.

ARIMA↗

DOE OSTI2025

Leveraging FPGA Advantages for Quicker Data Processing for LBNF

The Long Baseline Neutrino Facility (LBNF) will deliver a 2.4 MW muon neutrino beam from Fermilab to the Deep Underground Neutrino Experiment (DUNE), requiring unprecedented precision in beamline alignment to achieve DUNE's neutrino oscillation measurement goals. Vertical misalignments of beamline components as small as 0.5 mm can contribute 6-7\% uncertainty in predicted neutrino flux, necessitating sub-0.1 mm alignment monitoring capabilities. The Horn Location Sensor (HLS) system employs frequency sweep interferometry (FSI) in a distributed hydrostatic leveling network to achieve the required precision under harsh radiation conditions up to 5000 kRad/year. Traditional FSI implementations suffer from laser sweep nonlinearities that degrade resolution and require computationally intensive post-processing corrections using gas reference cells. This work presents a real-time FPGA-based implementation of the HLS data acquisition and processing system using a sweep tracker interferometer for dynamic sweep linearization. The system utilizes a PYNQ-Z2 FPGA with programmable logic implementing parallel 16k-point FFT processing across four channels, synchronized by the sweep tracker signal to eliminate post-processing requirements. Spectral performance testing demonstrates significant improvements in peak sharpness compared to traditional fixed-frequency digitization. The FPGA implementation enables real-time displacement monitoring with processing speeds orders of magnitude faster than software-based approaches, essential for the operational requirements of LBNF's eventual distributed sensor network. This advancement in real-time FSI processing directly supports DUNE's precision neutrino physics program by providing the rapid feedback necessary for maintaining stringent beamline alignment tolerances during high-power beam operations.

Rossel, Jacob↗

DOE OSTI2025

Real-Time FPGA Implementation For Frequency Sweep Interferometry In The LBNF Complex

Rossel, A. Jacob [Fermilab; Unlisted]↗

DOE OSTI2019

Use of Thermistor Temperature Sensors for Cyber-Physical System Security

The last few decades have seen a large proliferation in the prevalence of cyber-physical systems. This has been especially highlighted by the explosive growth in the number of Internet of Things (IoT) devices. Unfortunately, the increasing prevalence of these devices has begun to draw the attention of malicious entities which exploit them for their own gain. What makes these devices especially attractive is the various resource constraints present in these devices that make it difficult to add standard security features. Therefore, one intriguing research direction is creating security solutions out of already present components such as sensors. Physically Unclonable Functions (PUFs) are one potential solution that use intrinsic variations of the device manufacturing process for provisioning security. In this work, we propose a novel weak PUF design using thermistor temperature sensors. Our design uses the differences in resistance variation between thermistors in response to temperature change. To generate a PUF that is reliable across a range of temperatures, we use a response-generation algorithm that helps mitigate the effects of temperature variation on the thermistors. We tested the performance of our proposed design across a range of environmental operating conditions. From this we were able to evaluate the reliability of the proposed PUF with respect to variations in temperature and humidity. We also evaluated the PUF’s uniqueness using Monte Carlo simulations.

Internet of Things (IoT)↗

DOE OSTI2024

Machine Learning Discrimination and Ultrasensitive Detection of Fentanyl Using Gold Nanoparticle-Decorated Carbon Nanotube-Based Field-Effect Transistor Sensors

The opioid overdose crisis is a global health challenge. Fentanyl, an exceedingly potent synthetic opioid, has emerged as a leading contributor to the surge in opioid-related overdose deaths. The surge in overdose fatalities, particularly due to illicitly manufactured fentanyl and its contamination of street drugs, emphasizes the urgency for drug-testing technologies that can quickly and accurately identify fentanyl from other drugs and quantify trace amounts of fentanyl. In this paper, gold nanoparticle (AuNP)-decorated single-walled carbon nanotube (SWCNT)-based field-effect transistors (FETs) are utilized for machine learning-assisted identification of fentanyl from codeine, hydrocodone, and morphine. The unique sensing performance of fentanyl led to use machine learning approaches for accurate identification of fentanyl. Employing linear discriminant analysis (LDA) with a leave-one-out cross-validation approach, a validation accuracy of 91.2% is achieved. Meanwhile, density functional theory (DFT) calculations reveal the factors that contributed to the enhanced sensitivity of the Au-SWCNT FET sensor toward fentanyl as well as the underlying sensing mechanism. Finally, fentanyl antibodies are introduced to the Au-SWCNT FET sensor as specific receptors, expanding the linear range of the sensor in the lower concentration range, and enabling ultrasensitive detection of fentanyl with a limit of detection at 10.8 fg mL –1 .

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗