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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 OSTI2022

Probabilistic estimation of depth-resolved profiles of soil thermal diffusivity from temperature time series

Abstract. Improving the quantification of soil thermal and physical properties is key to achieving a better understanding and prediction of soil hydro-biogeochemical processes and their responses to changes in atmospheric forcing. Obtaining such information at numerous locations and/or over time with conventional soil sampling is challenging. The increasing availability of low-cost, vertically resolved temperature sensor arrays offers promise for improving the estimation of soil thermal properties from temperature time series, and the possible indirect estimation of physical properties. Still, the reliability and limitations of such an approach need to be assessed. In the present study, we develop a parameter estimation approach based on a combination of thermal modeling, sliding time windows, Bayesian inference, and Markov chain Monte Carlo simulation to estimate thermal diffusivity and its uncertainty over time, at numerous locations and at an unprecedented vertical spatial resolution (i.e., down to 5 to 10 cm vertical resolution) from soil temperature time series. We provide the necessary framework to assess under which environmental conditions (soil temperature gradient, fluctuations, and trend), temperature sensor characteristics (bias and level of noise), and deployment geometries (sensor number and position) soil thermal diffusivity can be reliably inferred. We validate the method with synthetic experiments and field studies. The synthetic experiments show that in the presence of median diurnal fluctuations ≥ 1.5 ∘C at 5 cm below the ground surface, temperature gradients > 2 ∘C m−1, and a sliding time window of at least 4 d the proposed method provides reliable depth-resolved thermal diffusivity estimates with percentage errors ≤ 10 % and posterior relative standard deviations ≤ 5 % up to 1 m depth. Reliable thermal diffusivity under such environmental conditions also requires temperature sensors to be spaced precisely (with accuracy to a few millimeters), with a level of noise ≤ 0.02 ∘C, and with a bias defined by a standard deviation ≤ 0.01 ∘C. Finally, the application of the developed approach to field data indicates significant repeatability in results and similarity with independent measurements, as well as promise in using a sliding time window to estimate temporal changes in soil thermal diffusivity, as needed to potentially capture changes in bulk density or water content.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

REFRACTORY COMPACT HEAT EXCHANGERS WITH EMBEDDED SENSORS ENABLED BY HYBRID ADVANCED SINTERING AND ADDITIVE APPROACH

Structural health monitoring (SHM) of compact heat exchangers (CHXs) operating in extreme environments is essential for ensuring system reliability, safety, and longevity. This study presents the development of high-temperature sensors fabricated via aerosol jet printing (AJP) using platinum ink, selected for its exceptional thermal stability, oxidation resistance, and electrical conductivity. AJP enables precise deposition of fine-feature sensor patterns onto complex geometries, making it well-suited for integration within CHX architectures. To enhance sensor durability, an alumina-based ceramic protective layer was printed over the platinum sensing elements. The sensors demonstrated stable, repeatable performance up to 900?°C during extended thermal cycling. A custom test setup was developed to evaluate sensor accuracy and robustness under steady-state and transient conditions. Substrate screening identified HG-1 ceramic-coated stainless steel as the most effective platform, offering strong adhesion and low resistance. Furthermore, electric field-assisted sintering (EFAS) was employed to embed the sensors into stainless steel 316L matrices without degrading their functionality. Post-embedding electrical tests confirmed sensor integrity, and initial characterization suggests strong potential for in-situ monitoring. This work provides a scalable strategy for integrating high-performance temperature sensors directly into refractory components, advancing embedded SHM technologies for harsh operating environments.

36 - MATERIALS SCIENCE↗
DOE OSTI2021

Fabrication and Characterization of Non-Equilibrium Plasma-Treated PVDF Nanofiber Membrane-Based Sensors

The effect of a self-pulsing non-equilibrium plasma discharge on piezoelectric PVDF nanofiber membrane was investigated. The plasma discharge was generated in air with a DC power source, with a discharge current of 0.012 mA, a nominal interelectrode separation of 1 mm, and discharge voltage of ~970 V. In a continuous fabrication process, the electrospinning method was used to generate thin nanofiber membrane with a flow rate of 0.7–1 mL h -1 and 25–27 kV voltage to obtain the nanofiber with high sensitivity and a higher degree of alignment and uniformity over a larger area. Plasma treatment was applied on both single layer and multi-layer (three layers) nanomembranes. In addition, simultaneously, the nanofiber membranes were heat-treated at a glass transition temperature (80–120 °C) and then underwent plasma treatment. Fourier-transform infrared (FTIR) spectroscopy showed that the area under the curve at 840 and 1272 cm -1 (β phase) increased due to the application of plasma and differential scanning calorimeter (DSC) indicated an increase in the degree of crystallinity. Finally, PVDF sensors were fabricated from the nanofibers and their piezoelectric properties were characterized. The results suggested that compared to the pristine samples the piezoelectric properties in the plasma and plasma-heat-treated sensors were enhanced by 70% and 85% respectively.

42 ENGINEERING↗
DOE OSTI2025

Direct ink writing of shear exfoliated two-dimensional nanomaterial- elastomeric multifunctional nanocomposite

Direct ink writing (DIW) of polymer nanocomposites with high loadings of two-dimensional (2D) nanofillers (graphene and hexagonal boron nitride (hBN)) is challenging because of potential clogging, use of hazardous solvents, and agglomeration. Here, in this work, a shear exfoliation and sieving method to prepare DIW ink with high loading of nanofillers produced from low-cost bulk layered materials such as graphite and bulk hBN powder for successful DIW printing without the use of any solvents, binders, or plasticizers. The single-step exfoliation technique resulted in a composite with substantial layer reduction along the c-axis, as confirmed by SEM, TEM, XRD, and Raman analysis. Incorporating exfoliated graphene (40 wt%) increased viscosity by ∼6 orders of magnitude due to enhanced particle–matrix interactions, leading to pronounced yield stress behavior and a yield stress of approximately 1598 Pa, which enabled excellent shape retention during extrusion. Using the DIW technique, porous structures such as desalination membranes, self-sensing bone scaffolds, thermal management coating, and serpentine strain sensors were fabricated. When tested in a direct contact membrane distillation setup, the fabricated membrane demonstrated a promising permeate flux of 21.85 Lm −2 h −1 and a salt rejection of 74.3 %. The fabricated serpentine sensor exhibited stable signal variations under cyclic tensile loading, with a working range of 0–200 % strain and a maximum gauge factor of 43,735. A cell culture test using the printed bone scaffold demonstrated promising cell attachment and proliferation. The DIW printed hBN nanocomposite exhibited reversible shape change under heat, demonstrating potential 4D printing capability and efficient thermal management when exposed to high heat or flame.

Desalination↗
DOE OSTI2023

Doped Lanthanum Chromite-refractory Based Composites Sensors for High Temperature Monitoring in Harsh Environments Systems

In order to test and monitor the operational stability and conditions of various energy, and manufacturing systems and their components, development of accurate sensors capable of operating at temperatures in excess of 1000 °C in various environments for long durations is required. In addition, many of these harsh-environment systems do not permit sensors to be directly inserted, so these sensors need to be embedded into thermal protective materials. In this work were developed high-temperature embedded thermocouples composed of various doped lanthanum chromites-refractory based composites synthesized by a mixed-oxide route and directly embedded into a Al2O3 based refractory. The electrical properties were specifically manipulated by altering the level of percolation of the conductive phase within the refractory constituent. Chemical stability of sensors was determined by phase development analysis by X-ray diffraction and X-ray photoelectron spectroscopy; Seebeck coefficients were determined by thermoelectric voltages measurements at temperature up to 1400 oC.

Perovskite LaCrO3, High-temperature conductivity, ↗
DOE OSTI2021

Ultrasensitive thermo-mechanical bolometer

A thermo-mechanical bolometer includes a substrate and a sensing component mounted on the substrate. The sensing element comprises (a) at least one thermal-actuation component mounted in parallel with the substrate and (b) a strain sensor mounted on the at least one layer of thermal-actuation component. The at least one thermal-actuation component alone or in combination (a) absorbs electromagnetic waves and converts energy from absorbed electromagnetic waves into a change in temperature and (b) converts the change in temperature into a deformation of the at least one layer. The strain sensor comprises a layer of fragments with a gap space between the fragments, wherein the strain sensor senses the deformation or mechanical movement and exhibits a change in electrical resistance in response to the sensed deformation or mechanical movement.

Lin, Yuxuan↗
DOE OSTI2024

Conceptual Design of Neutron Sensor Qualification Device

The Advanced Sensors and Instrumentation Program at Idaho National Laboratory has been formulating strategies to qualify sensors for use in nuclear environments, particularly in irradiation experiments and advanced reactors. When qualifying neutron sensors for use in high-temperature environments, the wide range of neutron flux levels and representative energy spectra presents significant challenges. This paper discusses the development of the Neutron Sensor Qualification Device (NQD), which is designed to test neutron sensors in high temperature controlled environments with known neutron spectra, addressing the spatial and spectral complexities of neutron fluxes in reactor cores. The proposed NQD will be situated in the exposure room at the Armed Forces Radiobiology Research Institute, thus affording a unique capability to expose sensors to high neutron and gamma fluxes. To achieve thermal control, the device will utilize a radiation-hardened tube furnace, accommodating multiple sensors and neutron activation dosimetry wires. Titanium, iron, and cobalt dosimeter wires are chosen from the American Society for Testing and Materials and International Reactor Dosimetry and Fusion File libraries as references for providing energy-dependent fluence measurements. The design ensures precise sensor positioning to minimize mutual shielding and flux perturbation, which are evaluated via Monte Carlo N particle Transport Code (MCNP) simulations. These simulations have informed the development of guidelines on sensor placement within the NQD. The NQD is essential to the qualification of neutron sensors for advanced reactor technologies. It enables controlled testing of a statistically significant number of sensors, thereby supporting assessments of sensor performance across various neutron flux levels and temperatures. This paper highlights the detailed planning for the NQD prototype, along with its inaugural irradiation (scheduled for fiscal year [FY] 2025). The results from this initial testing will be fundamental in evaluating the device’s performance and establishing measurement uncertainty for in-pile neutron sensor measurements.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2020

Q4FY20 Quarterly Report. LL20-AM-sensor

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. Project is 13 months into the 30 month on complete project plan. We are continuing effort on 3 main technical thrusts: algorithm development, multi-material additive manufacturing process exploration, and sensor/optics design and engineering. In FY20 we underspent the initial budget, partly due to work restrictions from Covid-19 pandemic, but are working to make up lost time

42 ENGINEERING↗
DOE OSTI2021

Q2FY21 Quarterly Report LL20-AM-sensor

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.

42 ENGINEERING↗
DOE OSTI2021

Q3FY21 Quarterly Report LL20-AM-sensor

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.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Analysis and improvement of the hot disk transient plane source method for low thermal conductivity materials

The hot disk transient plane source (TPS) method is a widely used standard technique (ISO 22007-2) for the characterization of thermal properties of materials, especially the thermal conductivity, k. Despite its well-established reliability for a wide variety of common materials, the hot disk TPS method is also known to suffer from a substantial systematic errors when applied to low-k thermal insulation materials. Here, we present a combined numerical and experimental study on the influence of the geometry of hot disk sensor on measured value of low-k materials. We demonstrate that the error is strongly affected by the finite thickness and thermal mass of the sensor's insulation layer was well as the corresponding increase of the effective heater size beyond the radius of the embedded metal heater itself. We also numerically investigate the dependence of the error on the sample thermal properties, confirming that the errors are worse in low-k samples. A simple correction function is also provided, which converts the apparent (erroneous) result from a standard hot disk TPS measurement to a more accurate value. A standard polyimide sensor was also optimized using both wet and dry etching to provide more accurate measurement directly. Experimentally corrected value of k for Airloy x56 aerogel and a commercial silica aerogel using the numerical correction factor derived based on the standard TPS sensor is in excellent agreement with the directly measured value from the TPS sensor using the optimized polyimide sensor. Finally, both of these methods can reduce the errors to less than 4% as compared to around 40% error of overestimation from raw values measured with the pristine sensor. Such results show that both the numerical correction to a pristine senor or an optimized sensor are capable of providing highly accurate value of thermal conductivity for such materials.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Preliminary Sensitivity Analysis for Sensors Impacts on Building Control Performance

This report describes the preliminary sensitivity analysis for sensor impacts on building control performance through the US Department of Energy’s Oak Ridge National Laboratory’s Flexible Research Platform (FRP-2) building. The rooftop unit system provides cooling and heating to the building. The main heating coil is a gas heating coil. Each zone is served by a variable air volume box with an electricity reheat coil. The rooftop unit and variable air volume box controls adopted the practical control sequences from ASHRAE Guideline 36-2018: High-Performance Sequences of Operation. For sensors, the incipient (time-changing) sensor errors, including bias sensor error and precision sensor error, are the inputs of interest. The outputs are energy consumption and thermal comfort (e.g., the predicted percentage of dissatisfied occupants). The large-scale simulation (3,600 cases) was conducted on a cloud platform by integrating sensor errors and ASHRAE Guideline 36 control sequences into an emulator based on the EnergyPlus simulation program with Python energy management system feature. The surrogate models were developed based on cloud simulation results. The uncertainty analysis showed that the sensor errors substantially affect building energy consumption and thermal comfort. The sensitivity analysis shows a ranking of sensor error impacts for each interested output item (e.g., cooling energy, reheat coil heating energy, predicted percentage of dissatisfied occupants). In FY 2022, sensor locations, types, and costs will be evaluated. The field test in Oak Ridge National Laboratory’s Flexible Research Platform building regarding sensor impacts will also be performed. Finally, a comparative analysis will be conducted based on the field test results and emulator results.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

Development of coated heat flux gauges for fast responding measurements

Thermal systems often exhibit transient behaviors that have important implications for the operation of the system and can be difficult to predict. For these reasons, experimental testing is often required to ensure system durability requirements are achieved. One important parameter governing the survivability of components in hot, high-stress environments is the heat flux into the part that dictates the temperature distribution for the component. However, sensors required to experimentally characterize heat fluxes in extreme environments must also be resilient. Here, this study presents the development of coated heat transfer gauges capable of robust, high-frequency measurements in turbine research facilities. The addition of a protective coating increases the durability of the gauge, but inherent of that coating is the attenuation of high-frequency temperature penetrations. As a result, this study first outlines the use of analytical solutions to define a gauge design for a specific frequency range and heat transfer, ensuring that subsurface signals can be rectified to surface conditions through inverse methods. Then, the fabrication of polyimide substrate sensors with a parylene-F coating is described. Micro surface heaters added to the custom sensors were used to determine important geometric and thermal properties necessary to calculate accurate surface heat flux. Ultimately, this work shows increased sensor robustness in a turbine test bed and experimentally validates that the frequency response of the fabricated sensors meet the design intent.

47 OTHER INSTRUMENTATION↗
DOE OSTI2023

Distributed Temperature Monitoring of Tundish Refractory Lining Using Optical Fiber Sensors

Distributed temperature monitoring can provide useful insights into the thermal conditions in the continuous caster tundish that can affect operating stability and cast quality, such as preheat conditions, superheat uniformity, fill height, and refractory wear. In the current study, fiber optic sensors were embedded into the refractory lining of a lab-scale tundish to record the temperature profiles during dry-out, preheating, and direct molten steel exposure to demonstrate sensor performance. Additional trials were performed with fiber optic sensors embedded in an industrial tundish used in production. Furthermore, the results demonstrate that fiber optic sensors using Rayleigh technology can provide accurate distributed temperature measurements in refractory lined vessels and provide useful information about the process.

Continuous Caster↗
DOE OSTI2024

Heat exchanger assemblies having embedded sensors

Heat exchanger assemblies are provided that can include: a heat exchanger housing; at least one primary conduit operably coupled to the heat exchanger housing and configured to convey a primary heat exchange fluid; at least one secondary conduit operably coupled to the heat exchanger housing and configured to convey a secondary heat exchange fluid; at least one thermal interface between the primary and secondary fluids; and at least one sensor operably engaged with the thermal interface. Heat exchanger assemblies including molten salt, liquid metal, or water/steam as part of the heat exchange fluids of the heat exchanger assembly are provided. The heat exchanger assemblies can include: at least one thermal interface between primary and secondary heat exchange fluids of the heat exchanger assembly; and a sensor operably engaged with the at least one interface.

Glass, III, Samuel W.↗
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

Remotely Sensed High‐Resolution Soil Moisture and Evapotranspiration: Bridging the Gap Between Science and Society

This paper reviews the current state of high‐resolution remotely sensed soil moisture (SM) and evapotranspiration (ET) products and modeling, and the coupling relationship between SM and ET. SM downscaling approaches for satellite passive microwave products leverage advances in artificial intelligence and high‐resolution remote sensing using visible, near‐infrared, thermal‐infrared, and synthetic aperture radar sensors. Remotely sensed ET continues to advance in spatiotemporal resolutions from MODIS to ECOSTRESS to Hydrosat and beyond. These advances enable a new understanding of bio‐geo‐physical controls and coupled feedback mechanisms between SM and ET reflecting the land cover and land use at field scale (3–30 m, daily). Still, the state‐of‐the‐science products have their challenges and limitations, which we detail across data, retrieval algorithms, and applications. We describe the roles of these data in advancing 10 application areas: drought assessment, food security, precision agriculture, soil salinization, wildfire modeling, dust monitoring, flood forecasting, urban water, energy, and ecosystem management, ecohydrology, and biodiversity conservation. We discuss that future scientific advancement should focus on developing open‐access, high‐resolution (3–30 m), sub‐daily SM and ET products, enabling the evaluation of hydrological processes at finer scales and revolutionizing the societal applications in data‐limited regions of the world, especially the Global South for socio‐economic development.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

High temperature and high pressure AlGaN/GaN electronics

Disclosed herein are devices, systems and methods useful for downhole sensors and electronics suitable for harsh thermal and mechanical environment associated with high-temperature geothermal drilling and high-temperature/high-pressure oil and gas drilling.

Ginley, David Samuel↗