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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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At least 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Out of the Lab: 3D Printing on Non-Ideal Surfaces

In this work, coaxial direct ink writing is utilized to print sensitive or encapsulated materials onto heterogeneous and rough substrates. By enclosing the core fluid within a rigid ceramic shell, continuity is maintained even when printing on substrates traditionally considered challenging. This work presents the development of a coaxial ceramic direct ink writing system and investigates co-flow dynamics through microfluidic principles. A specially designed coaxial nozzle enables the co-extrusion of an alumina shell, with indium-tin-oxide inks serving as the core material. This approach allows the fabrication of core-shell ceramic structures suitable for future high-temperature applications on rough surfaces. The colloidal inks are tailored to achieve the necessary rheological properties and sintering performance. Additionally, flow simulations, guided by microfluidic co-flow principles, are employed to define the processing parameters for coaxial printing, ensuring precise control over the core-shell architectures. Physical modeling is further applied to study core deformation and eccentricity. These simulations are experimentally validated, supporting the successful deposition of coaxial ceramic features on heterogeneous, high-temperature ceramic substrates.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2021

Optimizing the differential connection schemes for detecting 3D magnetic perturbations in DIII-D

Optimizing the differential pair connection scheme (i.e. the set of pairs) of a toroidal array of magnetic sensors dedicated to measuring slowly rotating asymmetric fields can enhance the mode number detection capability and failure-resilience. In this work the condition number obtained from singular value decomposition (SVD) of the design matrix is used as a metric to evaluate the quality of a connection scheme. A large number of possible pair connections are usually available, so evaluating all of them may require extensive use of computational resources and can be very time consuming. Alternative methods to reduce the number of pairs evaluated without losing the capabilities of toroidal mode detection are presented in this paper. Here, three examples of the applications of such analysis for the 3D magnetic diagnostic system of DIII-D are also presented: the addition of two new toroidal arrays with n > 3 detection capabilities, the modification of an existing toroidal array in the low field side of the machine to accommodate the addition of a helicon antenna, and the design of changes in several toroidal arrays in the high field side to accommodate the addition of a lower hybrid current drive antenna on the center post.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

System Calibration Including Time Delay Estimation for GNSS/INS-Assisted Pushbroom Scanners Onboard UAV Platforms

Unmanned aerial vehicles (UAVs ) equipped with imaging sensors and integrated global navigation satellite system/inertial navigation system (GNSS/INS ) units are used for numerous applications. Deriving reliable 3D coordinates from such UAVs is contingent on accurate geometric calibration, which encompasses the estimation of mounting parameters and synchronization errors. Through a rigorous impact analysis of such systematic errors, this article proposes a direct approach for spatial and temporal calibration (estimating system parameters through a bundle adjustment procedure) of a GNSS/INS -assisted pushbroom scanner onboard a UAV platform. The calibration results show that the horizontal and vertical accuracies are within the ground sampling distance of the sensor. Unlike for frame camera systems, this article also shows that the indirect approach is not a feasible solution for pushbroom scanners due to their limited ability for decoupling system parameters. This finding provides further support that the direct approach is recommended for spatial and temporal calibration of UAV pushbroom scanner systems.

47 OTHER INSTRUMENTATION↗
DOE OSTI2023

Machine Learning Enabled Sensor Fusion for In-Situ Defect Detection in Laser Powder Bed Fusion

Laser Powder Bed Fusion (L-PBF) Additive Manufacturing (AM) is among the metal 3D printing technologies most broadly adopted by the manufacturing industry. The current industry qualification paradigm for critical-application L-PBF parts relies heavily on expensive non-destructive inspection techniques such as X-Ray Computed Tomography (XCT), which significantly limits the use-cases of L-PBF. In situ monitoring of the process promises a less expensive alternative to ex situ testing, but existing sensor technologies and data analysis techniques struggle to detect sub-surface flaws (e.g., porosity and cracking) on production-scale L-PBF printers. RTX Technologies Research Center (RTRC) has licensed ORNL’s Peregrine software package – a printer- and camera-agnostic data analytics tool designed specifically for detecting process anomalies using in situ data collected during powder bed printing. The goal of this project was to feed temporally rich, multi-modal sensor data, including visible light, integrated near infrared (NIR), and spatially mapped co-axial melt pool thermal emission data into Peregrine to enable detection of subsurface flaws. XCT data was used as ground truth training data to allow Peregrine’s deep learning algorithms to recognize anomalies in these complex data streams in both test artifacts and industrially relevant geometries. Completion of this program has seen the successful implementation of multi-modal, multi-layer sensor data footprints for training of machine learning models in Peregrine. Flaws detected in XCT data have been successfully detected directly from this in situ data footprint, and initial analyses of the in situ probability-of-detection has been conducted, showing performance levels commensurate with traditional non-destructive evaluation (NDE) methods. The in situ monitoring methodology was then applied to an industrially relevant component that was using post-build NDE, highlighting the utility of the proposed method for hard-to-inspect AM components. As a direct result of this program, two journal manuscripts [1], [2] have been published in Additive Manufacturing, with additional manuscripts planned following program completion.

36 MATERIALS SCIENCE↗
DOE OSTI2020

An Algorithm to Retrieve Total Precipitable Water Vapor in the Atmosphere from FengYun 3D Medium Resolution Spectral Imager 2 (FY-3D MERSI-2) Data

The atmosphere has substantial effects on optical remote sensing imagery of the Earth’s surface from space. These effects come through the functioning of atmospheric particles on the radiometric transfer from the Earth’s surface through the atmosphere to the sensor in space. Precipitable water vapor (PWV), CO 2 , ozone, and aerosol in the atmosphere are very important among the particles through their functioning. This study presented an algorithm to retrieve total PWV from the Chinese second-generation polar-orbiting meteorological satellite FengYun 3D Medium Resolution Spectral Imager 2 (FY-3D MERSI-2) data, which have three near-infrared (NIR) water vapor absorbing channels, i.e., channel 16, 17, and 18. The algorithm was improved from the radiance ratio technique initially developed for Moderate-Resolution Imaging Spectroradiometer (MODIS) data. MODTRAN 5 was used to simulate the process of radiant transfer from the ground surfaces to the sensor at various atmospheric conditions for estimation of the coefficients of ratio technique, which was achieved through statistical regression analysis between the simulated radiance and transmittance values for FY-3D MERSI-2 NIR channels. The algorithm was then constructed as a linear combination of the three-water vapor absorbing channels of FY-3D MERSI-2. Measurements from two ground-based reference datasets were used to validate the algorithm: the sun photometer measurements of Aerosol Robotic Network (AERONET) and the microwave radiometer measurements of Energy’s Atmospheric Radiation Measurement Program (ARMP). The validation results showed that the algorithm performs very well when compared with the ground-based reference datasets. The estimated PWV values come with root mean square error (RMSE) of 0.28 g/cm 2 for the ARMP and 0.26 g/cm 2 for the AERONET datasets, with bias of 0.072 g/cm 2 and 0.096 g/cm 2 for the two reference datasets, respectively. The accuracy of the proposed algorithm revealed a better consistency with ground-based reference datasets. Thus, the proposed algorithm could be used as an alternative to retrieve PWV from FY-3D MERSI-2 data for various remote sensing applications such as agricultural monitoring, climate change, hydrologic cycle, and so on at various regional and global scales.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Development of a forced advection sampling technique (FAST) for quantification of methane emissions from orphaned wells

Abstract. Orphaned wells, meaning unplugged and non-producing wells lacking responsible owners, pose a significant and undersampled environmental challenge due to their vast number and unknown associated emissions. We propose, develop and test an alternative method for estimating emissions from orphaned wells using a forced advection sampling technique (FAST) that can overcome many of the limitations in current methods (cost, accuracy, safety). In contrast to existing ambient Gaussian plume methods, our approach uses a fan-generated flow to force advection between the emission source and a point methane (CH4) sensor. The fan flow field is characterized using a colocated sonic anemometer to measure the 3D wind profile generated by the fan. Using time-series measurements of CH4 concentration and wind, a simple estimate of the CH4 emission rate of the source can be inferred. The method was calibrated using outdoor controlled-release experiments and then tested on four orphaned wells in Lufkin, TX, and Osage County, OK. Our results suggest that the FAST method can provide a low-cost, portable, fast and safe alternative to existing methods with reasonable estimates of orphaned well emissions over a range of leak rates below 40 g h−1 and within certain geometric and atmospheric constraints.

Dubey, Mohit L↗
DOE OSTI2021

Hybrid printing of wearable piezoelectric sensors

Piezoelectricity provides an ideal electromechanical mechanism with emerging applications in wearable devices due to its simplicity and self-powered nature. However, the 3D printing of piezoelectric devices still faces many challenges, including material printability, high energy poling process, and low dimensional accuracy. This study demonstrates, for the first time, a tellurium nanowire-based piezoelectric device fabricated by a hybrid printing method integrating highly complementary aerosol jet printing and extrusion printing in a single printing platform. The aerosol-jet-printed tellurium nanowire demonstrates piezoelectric properties without the need for any poling processing due to the unique properties of the tellurium nanowires. The silver nanowire electrodes printed by aerosol jet printing demonstrate excellent conductivity and stretchability without the need for sintering. An extrusion method is employed to print the silicone films, which serve as the stretchable substrate and the electrical insulation layers between the printed tellurium and silver. The printed wearable piezoelectric devices were attached to a human wrist to detect different hand gestures and to a human neck to detect heartbeat without using an external power source. In conclusion, the fully printed, sintering-free and poling-free, and stretchable piezoelectric device opens enormous opportunities for facile integration with a broad range of printed electronics and wearable devices.

47 OTHER INSTRUMENTATION↗
DOE OSTI2026

Thermal Performance of Spandrel Assemblies in Glazed Wall Systems: Laboratory Test Design – Challenges and Test Results

Accurate thermal performance calculation procedures for opaque spandrel areas in curtain wall and window wall systems are essential for rating systems when comparing spandrel systems. However, there is a lack of consensus in thermal modeling needed for accurately characterizing heat transfer through spandrel assemblies due to the complex arrangement of materials and structural components. Several studies indicate that conventional 2D thermal simulations may overestimate R-values by 30% compared to physical testing and 3D simulations. Detailed simulations and well-curated laboratory test data are necessary to build confidence in simulation models, which will later be used to develop correlations to improve widely used conventional 2D thermal simulations. This study aims to experimentally test heat transfer through various spandrel assemblies to validate 3D simulation models. Also, the challenges of conducting a thorough testing design along with the solutions would be documented. The team developed a design for testing spandrel assemblies, making appropriate modifications to the existing heat, air, and moisture (HAM) chamber to accommodate the testing needs. Two moveable baffles were designed and fabricated to guide airflow direction parallel to the test article surface. The data acquisition capabilities in the chamber were upgraded to add more than two hundred sensors to the climate and indoor side of the chamber. The goal is to provide a quality dataset for validating complex 3D modeling simulations, which will be used to develop improved thermal simulation techniques that more accurately represent the thermal behavior of spandrel assemblies and their integration within the building envelope. This paper will summarize the results for the boundary conditions of the testing and the temperature variation across different locations of the spandrel assemblies.

Kunwar, Niraj [ORNL] (ORCID:0000000263457652)↗
DOE OSTI2025

Multiscale aperture synthesis imager

Synthetic aperture imaging has enabled breakthrough observations from radar to astronomy. However, optical implementation remains challenging due to stringent wavefield synchronization requirements among multiple receivers. Here we present the multiscale aperture synthesis imager (MASI), which utilizes parallelism to break complex optical challenges into tractable sub-problems. MASI employs a distributed array of coded sensors that operate independently yet coherently to surpass the diffraction limit of single receiver. It combines the propagated wavefields from individual sensors through a computational phase synchronization scheme, eliminating the need for overlapping measurement regions to establish phase coherence. Light diffraction in MASI naturally expands the imaging field, generating phase-contrast visualizations that are substantially larger than sensor dimensions. Without using lenses, MASI resolves sub-micron features at ultralong working distances and reconstructs 3D shapes over centimeter-scale fields. MASI transforms the intractable optical synchronization problem into a computational one, enabling practical deployment of scalable synthetic aperture systems at optical wavelengths.

electrical and electronic engineering↗
DOE OSTI2024

Heuristic algorithms for design of integrated monitoring of geologic carbon storage sites

Designs for Risk Evaluation and Management (DREAM) is a tool developed under the National Risk Assessment Partnership (NRAP) to enhance geologic carbon storage safety and efficiency. Using potential leakage scenarios generated externally by the users preferred history-matching approach, DREAM constructs ideal combinations of sensor locations in the right place at the right time to detect as many leaks as possible, detect them as early as possible, and minimize cost. This user-friendly tool, developed in Java, features a window-based GUI for input and a 3D visualization tool for viewing the domain space and optimized monitoring plans. DREAM's latest version accommodates real-world usage by allowing for joint optimization of wellbore point sensor placements and surface geophysics survey geometries, and by using more efficient multi-objective optimization algorithms. We show an example where, these two improvements combined allow us to support containment assurance and go from detecting 80–90 % of the potential CO 2 leakage to +99.7 %, a step-change improvement that can make the deciding difference in whether a site is suitable for geologic carbon storage. Though developed for geologic carbon storage, this tool would be equally applicable in many surface or offshore environmental monitoring projects.

58 GEOSCIENCES↗
DOE OSTI2020

Machine Vision-based Robot Manipulators for Nuclear Applications - 20370

Decommissioning and dismantling of nuclear facilities are major challenges facing the nuclear industry. Robot manipulators with capabilities of restoring nuclear structures and significantly prolonging nuclear power generation in addition to their applications in decommissioning and dismantling (D and D) would immensely ease the above-mentioned challenge. Ability to remotely sense/monitor and analyze dangerous and hazardous environments such as nuclear reactors as well as performing reparatory tasks in such environments using robot manipulators require additional information from vision sensors. Structural sample collection and inspection as well as restoration require object and position information. Computer vision is used to obtain precise 3D position information. The current work uses the Sawyer robot with the integrated Cognex camera. The research presents an approach to facilitate and improve operations in a nuclear reactor using robotic vision control. The vision control system is modeled with Augmented Image Space-based visual servoing approach. Results showing accurate robot control. Object recognition is used to recognize the image and calculate it poses. To transform coordinates of the object's pose from the camera frame to the robotic frame transformation matrices are employed. Future work will employ a 3D camera (with depth information) using Denso robot. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2022

Concept of Operations of Next-Generation Traffic Control Utilizing Infrastructure-Based Cooperative Perception

This paper provides a system architecture for an infrastructure-based cooperative perception fusion engine for next-generation traffic control. This engine will provide a complete state-space digital representation with measurable accuracy to support a wide-range of applications. The architecture includes inputs, functional flow, data standardization recommendations, outputs, and supported applications. The cooperative perception engine addresses critical needs with respect to accelerating the benefits of automation through intelligent roadway infrastructure, which complements and accelerates connected and automated vehicle (CAV) technology. The cooperative perception acquires and fuses information from sensors (radar, LiDAR, and cameras) and CAVs to perceive roadway traffic states of moving objects, creates a complete 3D digital representation of that state-space, and communicates it to downstream application such as intelligent signal control, safety and energy applications, and cooperate driving applications. The intelligent roadway infrastructure approach, as opposed to a vehicle-centric approach, is more scalable because it can be deployed to the roughly 300,000 signalized intersections more readily than over 300 million vehicles in the United States, and accrues early-stage benefits equitable to all roadway users addressing safety, equity, fuel efficiency, and greenhouse gas reduction.

ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2020

Autonomous Radiation Mapping and Quantification using an Unmanned Ground Vehicle. Part II - Autonomous Navigation

Nuclear sites across the Unites States and other nations in the world, are prone to extreme radiation effects. To understand the radiation hazards, plan the cleanup efforts; and to meet the quality standards and guidelines, it is important to accurately characterize any nuclear facility. One of the current methods in characterizing facilities is the use of advanced autonomous systems. These are safe, efficient, and cost-effective tools, which can safely deploy state-of-the-art instrumentation without exposing workers to radiation risks. Conventional methods of taking radiation measurements by hand within or around the containment areas, and analyzing the collected data to obtain the result are: Ineffective, Puts scientists at risk of Radiation, Not cost-effective. The platform uses the Robotic Operating Systems (ROS) to integrate multiple sensors seamlessly. It can operate near real time by using a distributed processing system to handle large amounts of data: Surrounding cameras, A multi-channel 3D Lidar, Manipulator arm, High-performance gamma-ray spectrometer.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2022

Coaxial Ceramic Direct Ink Writing on Heterogenous and Rough Surfaces: Investigation of Core–Shell Interactions

In this work, coaxial conductor–ceramic direct ink writing enables the printing of sensitive or encapsulated materials onto heterogeneous and rough substrates. While encasing the core fluid within a stiff ceramic shell, continuity may be maintained, even while printing onto conventionally challenging substrates. Here, we report the development of a coaxial ceramic direct ink writing suite and explore coflow interrelationships based on microfluidic principles. A coaxial nozzle is designed to facilitate the coextrusion of an alumina shell, whereas indium–tin-oxide inks constitute the core. In this manner, a core–shell ceramic element may be printed onto rough substrates for future high-temperature applications. Colloidal inks are engineered to provide the required rheological and sintering performance. Moreover, flow simulations in conjunction with microfluidic coflow principles are used to explore the coaxial printing processing space, thus controlling the core–shell architectures. Physical modeling is further used to analyze core deformations and eccentricity. As a result, simulations are validated experimentally, and the analyses are used to deposit coaxial ceramic features onto heterogeneous, high-temperature ceramic substrates.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2021

Tardigrade (NA-22 Quarterly Report)

Tardigrade is an effort to create tunable thermal expansion materials for use in a ruggedized lens housing. This requires new computational algorithms to model and predict thermal performance of meta-materials composed of multiple structured base materials and void-space, along with matching and developing 3D print technology to demonstrate the housing. The project is 24 months into the 36-month plan. We are continuing effort on 3 main technical thrusts: material design algorithm development (transitioning into full 3D design), multi-material additive manufacturing process exploration, and sensor/optics design and engineering. In the last quarter, we have focused on developing the code for 3D Topology Optimization, building data sets for 2D autoencoder training, and finishing lens housing engineering for the microbolometer based test sensor. We are exploring 2 potential multi-material AM technologies, a polymer-based technique in development at LLNL and a metal SLS system produced by Aconity, called the AeroSint deposition head.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Tardigrade (Quarterly Report Q1 FY2022)

Tardigrade is an effort to create tunable thermal expansion materials for use in a ruggedized lens housing. This requires new computational algorithms to model and predict thermal performance of meta-materials composed of multiple structured base materials and void-space, along with matching and developing 3D print technology to demonstrate the housing. The project is 27 months into the 36-month plan. We are continuing effort on 3 main technical thrusts: material design algorithm development (transitioning into full 3D design), multi-material additive manufacturing process exploration, and sensor/optics design and engineering. In the last quarter, we have focused on developing the code for 3D Topology Optimization, building data sets for 2D autoencoder training, and finishing lens housing engineering for the microbolometer based test sensor. We are exploring 2 potential multi-material AM technologies, a polymer-based technique in development at LLNL and a metal SLS system produced by Aconity, called the AeroSint deposition head.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Root system architecture and environmental flux analysis in mature crops using 3D root mesocosms

Current methods of root sampling typically only obtain small or incomplete sections of root systems and do not capture their true complexity. To facilitate the visualization and analysis of full-sized plant root systems in 3-dimensions, we developed customized mesocosm growth containers. While highly scalable, the design presented here uses an internal volume of 45 ft 3 (1.27 m 3 ), suitable for large crop and bioenergy grass root systems to grow largely unconstrained. Furthermore, they allow for the excavation and preservation of 3-dimensional root system architecture (RSA), and facilitate the collection of time-resolved subterranean environmental data. Sensor arrays monitoring matric potential, temperature and CO 2 levels are buried in a grid formation at various depths to assess environmental fluxes at regular intervals. Methods of 3D data visualization of fluxes were developed to allow for comparison with root system architectural traits. Following harvest, the recovered root system can be digitally reconstructed in 3D through photogrammetry, which is an inexpensive method requiring only an appropriate studio space and a digital camera. We developed a pipeline to extract features from the 3D point clouds, or from derived skeletons that include point cloud voxel number as a proxy for biomass, total root system length, volume, depth, convex hull volume and solidity as a function of depth. Ground-truthing these features with biomass measurements from manually dissected root systems showed a high correlation. We evaluated switchgrass, maize, and sorghum root systems to highlight the capability for species wide comparisons. We focused on two switchgrass ecotypes, upland (VS16) and lowland (WBC3), in identical environments to demonstrate widely different root system architectures that may be indicative of core differences in their rhizoeconomic foraging strategies. Finally, we imposed a strong physiological water stress and manipulated the growth medium to demonstrate whole root system plasticity in response to environmental stimuli. Hence, these new “3D Root Mesocosms” and accompanying computational analysis provides a new paradigm for study of mature crop systems and the environmental fluxes that shape them.

59 BASIC BIOLOGICAL SCIENCES↗