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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 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Computed Tomography Scanning and Geophysical Measurements of the Fayetteville Shale Formation from the Nixon B #1-7 Well

The computed tomography (CT) facilities and the Multi-Sensor Core Logger (MSCL) at the National Energy Technology Laboratory (NETL) in Morgantown, West Virginia were used to characterize core from the Fayetteville and Pitkin formations. This core came from a vertical well drilled by Southwestern Energy (Nixon B #1-7 well) and characterized as part of the U.S. Department of Energy’s (DOE) Fossil Energy and Carbon Management Onshore portfolio’s focus on unconventional shale plays. The primary impetus of this work is to characterize Fayetteville Shale core, from an unconventional shale play in Northwestern Arkansas, that is relatively under-reported on when compared to larger unconventional resources in the continental U.S.

58 GEOSCIENCES↗
DOE OSTI2025

Measuring thermal curing induced shrinkage of material extrusion based additive manufacturing silicone elastomer lattices by X-ray computed tomography

Thermal curing induces shrinkage in material extrusion based additive manufacturing silicone elastomer samples, resulting in discrepancies between as printed and final geometries. Knowing the extent to which the samples change in shape and size allows us to make appropriate modifications to the printing design to better control the geometry of the samples. We present an X-ray computed tomography (CT) based approach to determine filament-level shrinkage due to thermal curing of silicone elastomer samples printed with direct ink writing (DIW). The approach relies on custom-designed build plates that are resistant to the elevated curing temperatures and that have sufficiently distinct X-ray absorption characteristics from the silicone elastomer to ensure adequate segmentation of the latter in X-ray imaging data. We implement the approach to evaluate shrinkage in DIW ‘log pile’ samples with three distinct strand arrangements and demonstrate of how filament-level information can be extracted from the X-ray CT data.

Additive manufacturing↗
DOE OSTI2024

Fabrication of a Point-Like Transmission Target for Reducing Computed Tomography Imaging Artifacts

In this study, we address the challenge of enhancing image quality and spatial resolution in computed tomography (CT) imaging by introducing simulation and fabrication of high aspect ratio, point-like transmission targets. Utilizing advanced electroplating techniques, traditionally employed in the fabrication of Through Substrate Via (TSV) interconnects for CMOS circuitry, we successfully embed copper targets within silicon substrates. This method allows us to create high-aspect-ratio features specifically designed for X-ray transmission targets, resulting in micro targets that exhibit a volume increase compared to conventional evaporated surface targets. Furthermore, we present simulation results of the X-ray spectrum generated by these targets, demonstrating their potential to significantly improve both image quality and spatial resolution in CT applications. Our findings suggest that leveraging advanced fabrication techniques can open new avenues for the development of enhanced imaging technologies in medical diagnostics and beyond.

47 OTHER INSTRUMENTATION↗
NASA NTRS2023

Investigating the Impact of X-Ray Computed Tomography Imaging on Soluble Organic Matter in the Murchison Meteorite: Implications for Bennu Sample Analyses

X-ray computed tomography (XCT) is a valuable reconnaissance tool for three-dimensional imaging and identification of distinct lithologies in extraterrestrial samples. It will be used as part of the preliminary examination of samples returned from asteroid (101955) Bennu by the Origins, Spectral Interpretation, Resource Identification, and Security–Regolith Explorer (OSIRIS-REx) mission. However, it must first be established whether x-rays generated during XCT could degrade or alter the organic composition of the returned samples by radiolysis. To test this, we split a crushed sample of the Murchison CM2 meteorite, kept one portion as a control, and irradiated the other portion up to the maximum x-ray dosage (~180 Gy) that a Bennu sample would experience during an XCT imaging experiment. We then extracted organic compounds from both splits and conducted (i) nontargeted soluble organic analyses to compare the chemical distributions of C-, H-, O-, N-, and S-bearing species and (ii) targeted measurements to quantify the abundances of 96 individual soluble organic molecules that included protein amino acids, amines, carboxylic acids, hydroxy acids, carbonyl compounds, polycyclic aromatic hydrocarbons, alcohols, sugars, and N-heterocycles. We found that XCT imaging of the Murchison meteorite had no measurable impact on the relative abundances or enantiomeric compositions of most of the soluble organic compounds targeted in this study. Elevated total abundances of several soluble organic compound classes were observed in the XCT-scanned Murchison sample relative to the control. This is likely related to particle size heterogeneity and specific surface area differences between the sample aliquots used for the extractions, rather than a result of the x-ray exposure. Assuming the samples returned from asteroid Bennu by OSIRIS-REx have a similar composition to carbonaceous chondrites, these data provide confidence that XCT will not significantly alter their soluble organic compositions.

Daniel P Glavin↗
DOE OSTI2024

Segmentation of RDX and TNT in X‐Ray Computed Tomography Reconstructions of Melt‐Cast Explosives

ABSTRACT Three‐dimensional mesoscale characterization of heterogeneous melt‐cast high explosives is challenging because of the difficulty differentiating binder from explosive crystals: two functionally different materials which are typically similar in density by design. Here, we report an algorithm which can differentiate hexahydro‐1,3,5‐trinitro‐1,3,5‐triazine (RDX) from 2,4,6‐trinitrotoluene (TNT) in x‐ray computed tomography (CT) volumes with tens of microns resolution. This method allows us to quantify RDX/TNT content, porosity, and RDX domain size. We calibrated the segmentation algorithm using simulated x‐ray CT volumes containing object models of RDX crystals within a TNT matrix. We then segmented and analyzed CT data for Composition B (Comp B), a 60/40 RDX/TNT mixture, and Cyclotol, a 75/25 RDX/TNT mixture. We examined melt‐cast samples fabricated with 100% theoretical maximum density (TMD) and 85% TMD. For the 100% TMD Comp B and Cyclotol samples, the RDX content values calculated by segmentation were 3% and 9% lower, respectively, than the values measured by high‐performance liquid chromatography on material from the same synthesis lots. This result is consistent with the expected underreporting of RDX content resulting from x‐ray CT resolution limits on RDX particles with diameters smaller than 25 µm. The 85% TMD samples were less accurately segmented with our algorithm due to the confounding presence of voids.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Porosity evolution under increasing tension in wire-arc additively manufactured aluminum using in-situ micro-computed tomography and convolutional neural network

Internal defects such as porosities are often formed in additively manufactured metal components. The pores nucleate, grow, and coalesce to form cracks under loads, leading to eventual catastrophic failure. Here, in this paper, the full-field porosity evolution, including pore growth and coalescence in a wire-arc additively manufactured (WAAM) aluminum alloy cylinder under tension is observed with in-situ X-ray micro-computed tomography (μCT). The pore size distribution, density, and tensile stress are calculated from the volumetric images analyzed by a convolutional neural network (CNN) algorithm, which provides rapid analysis of 12,950 slice images from μCT volumetric images at the reference state and 13 tensile strains. The results show the quantitative evolution of the growth and coalescence of macropores under tension. A strong correlation is found between the local pore volume fraction and the true tensile stress when the tensile strain is larger than 5%.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Computed Tomography Scanning and Petrophysical Measurements of the Wellington KGS 2-32 Core

This report describes the use of the computed tomography facilities and the Multi-Sensor Core Logger at the National Energy Technology Laboratory in Morgantown, West Virginia to characterize core from the Wellington KGS 2-32 well (API 15-191-22770). Core from the well was obtained as part of the Small-Scale Field Test Demonstrating Carbon Dioxide Sequestration in Arbuckle Saline Aquifer and by CO 2 -Enhanced Oil Recovery at Wellington Field, Sumner County, Kansas (DE-FE0006821). The primary impetus of this work was to capture a detailed a digital representation of the core from the Wellington KGS 2-32 well (Sumner County, Kansas). The collaboration between the U.S. Department of Energy’s (DOE) NETL and the Kansas Geological Survey (KGS) at the University of Kansas enables other research entities to access information about this potential carbon storage location and formations. The resultant datasets are presented in this report and can be accessed from NETL's Energy Data eXchange (EDX) online system using the following link: https://edx.netl.doe.gov/dataset/wellington2-32-core.

47 OTHER INSTRUMENTATION↗
DOE OSTI2025

Multiscale Characterization of Additive Manufacturing Components with Computed Tomography, 3D X-ray Microscopy, and Deep Learning

Additive manufacturing (AM) facilitates the creation of complex-geometry parts, driving advancements in lightweight aerospace components, high-efficiency engine cooling channels, and customized medical implants. However, ensuring the quality and reliability of AM parts remains challenging due to internal defects, surface irregularities, porosity, and residual trapped powder, which are often inaccessible to traditional inspection methods. Recent developments in X-ray computed tomography (XCT) and 3D X-ray microscopy (XRM), particularly systems equipped with resolution-at-a-distance (RaaD™) capabilities, enable high-resolution, non-destructive evaluation of AM components across multiple scales, from sub-micrometer to macroscopic levels. This paper explores modern XCT and XRM techniques for multiscale characterization of AM parts, focusing on their ability to detect and analyze defects such as porosity, cracks, inclusions, and surface roughness, while offering insights into defect formation mechanisms, material properties, and process-induced variations. The integration of deep learning (DL) frameworks, including Simurgh, DeepRecon, and DeepScout, enhances XCT/XRM workflows by reducing scan times, improving resolution recovery, and enabling accurate defect detection even with limited projection data. These DL-based methods overcome limitations of traditional reconstruction techniques, enabling faster, more reliable characterization of dense materials like Inconel 718 and novel alloys such as AlCe. Applications include process parameter optimization, high-throughput quality control, and multistage AM process evaluation, with DL-enhanced workflows accelerating analysis times from weeks to days. Correlative imaging approaches further validate XCT and XRM data against scanning electron microscopy (SEM) images of physically sectioned samples, confirming the accuracy of DL-based reconstructions and enabling comprehensive defect analysis. While challenges remain in generalizing DL models to diverse materials and imaging conditions, improvements in resolution, noise reduction, and defect detection highlight the transformative potential of these methods. This multiscale and correlative approach enables precise identification and correlation of microstructural features with the overall performance of AM components. By integrating advanced XCT, XRM, and DL techniques, this paper demonstrates a significant leap forward in AM characterization, offering valuable insights into the relationships between processing parameters, microstructure, and part performance, and driving innovations that enhance the quality and reliability of AM products for demanding industrial applications.

Additive manufacturing↗
DOE OSTI2022

Characterization of anisotropic mechanical properties of polymer composites from a hybrid additive manufacturing-compression molding process using x-ray computer tomography

In this study, anisotropic stiffness tensors were reconstructed based on fiber orientation distributions obtained from X-ray computer tomography (xCT). A preform was manufactured via a big area additive manufacturing (BAAM) system with carbon fiber (CF) filled acrylonitrile butadiene styrene (ABS). The tailored preform from additive manufacturing (AM) was used in the compression molding (CM) process to produce a low-void high-performance thermoplastic composite panel. An xCT technique was employed to detect the fiber orientations in CF/ABS composites manufactured via three different methods: AM from BAAM, extrusion compression molding (ECM), and AM-CM. The anisotropic stiffness tensor was obtained from the composite panel manufactured via the three manufacturing methods (AM, ECM, and AMCM). A micromechanics theory was used to obtain the orthotropic stiffness tensors of the composite panels and compared with the experimental values. The predicted stiffness tensors of AM and AM-CM composite panels were used to study the deformation characteristics of a steering wheel during airbag deployment by performing finite element analysis (FEA). The approach developed in this study can be utilized for evaluating high-performance composites.

Pokkalla, Deepak↗
NASA NTRS2017

Mapping Bone Mineral Density Obtained by Quantitative Computed Tomography to Bone Volume Fraction

Methods for relating or mapping estimates of volumetric Bone Mineral Density (vBMD) obtained by Quantitative Computed Tomography to Bone Volume Fraction (BVF) are outlined mathematically. The methods are based on definitions of bone properties, cited experimental studies and regression relations derived from them for trabecular bone in the proximal femur. Using an experimental range of values in the intertrochanteric region obtained from male and female human subjects, age 18 to 49, the BVF values calculated from four different methods were compared to the experimental average and numerical range. The BVF values computed from the conversion method used data from two sources. One source provided pre bed rest vBMD values in the intertrochanteric region from 24 bed rest subject who participated in a 70 day study. Another source contained preflight vBMD values from 18 astronauts who spent 4 to 6 months on the ISS. To aid the use of a mapping from BMD to BVF, the discussion includes how to formulate them for purpose of computational modeling. An application of the conversions would be used to aid in modeling of time varying changes in vBMD as it relates to changes in BVF via bone remodeling and/or modeling.

Pennline, James A.↗
NASA NTRS2011

A Novel Automated Method for Analyzing Cylindrical Computed Tomography Data

A novel software method is presented that is applicable for analyzing cylindrical and partially cylindrical objects inspected using computed tomography. This method involves unwrapping and re-slicing data so that the CT data from the cylindrical object can be viewed as a series of 2-D sheets in the vertical direction in addition to volume rendering and normal plane views provided by traditional CT software. The method is based on interior and exterior surface edge detection and under proper conditions, is FULLY AUTOMATED and requires no input from the user except the correct voxel dimension from the CT scan. The software is available from NASA in 32- and 64-bit versions that can be applied to gigabyte-sized data sets, processing data either in random access memory or primarily on the computer hard drive. Please inquire with the presenting author if further interested. This software differentiates itself in total from other possible re-slicing software solutions due to complete automation and advanced processing and analysis capabilities.

Roth, D. J.↗
DOE OSTI2026

State-of-Charge Investigation of Lithium Manganese Dioxide Primary Batteries Utilizing X-ray Computed Tomography

Lithium primary batteries (LPBs) represent a class of energy storage devices, uniquely suited for mission-critical applications including emergency backup power, aerospace and defense electronics, implantable medical devices, and remote sensing. Despite their technological maturity and distinct advantages over rechargeable lithium-ion batteries (i.e., superior shelf life and operational simplicity), state-of-charge (SoC) estimation in these batteries remains a persistent challenge due to the lack of a reliable, quantifiable diagnostic technique. In this work, we investigate X-ray computed tomography (X-CT) as a transformative and accurate SoC estimation technique for LPBs. Results gained through X-CT measurements reveal systematic, quantifiable structural changes in cathode morphology and geometry during discharge, establishing a direct structural basis for SoC estimation, with a maximum relative standard deviation of 2.3%. This work establishes a pathway toward operando, imaging-driven SoC diagnostics that can significantly enhance the reliability of SoC estimation in LPBs.

25 ENERGY STORAGE↗
DOE OSTI2023

Computed Tomography Scanning and Geophysical Measurements of Appalachian Basin Core from the Jones and Laughlin #1 Well, Beaver County, PA

The computed tomography (CT) facilities and the Multi-Sensor Core Logger (MSCL) at the National Energy Technology Laboratory (NETL) in Morgantown, West Virginia, were used to characterize Appalachian Basin core from Beaver County, Pennsylvania. The primary impetus of this work is a collaboration between the U.S. Department of Energy (DOE) and the Pennsylvania Geological Survey to characterize and make publicly available core information from the Onondaga-Huntersville formations of the Appalachian Basin. This stratigraphic well and the core data produced in this report will aid in understanding the structural complexities of the Onondaga-Huntersville formations. The resultant datasets are presented in this report and can be accessed from NETL's Energy Data eXchange (EDX) online system using the following link: https://edx.netl.doe.gov/dataset/jonesandlaughlin1well. All equipment and techniques used were non-destructive, enabling future examinations and analyses to be performed on these cores. Fractures, discontinuities, and millimeter-scale features were readily detectable with imaging performed with the NETL medical CT scanner over the entire core. Qualitative analysis of the medical CT images, coupled with X-ray fluorescence (XRF), and magnetic susceptibility measurements from the MSCL were useful in identifying zones of interest for further study. Targeted higher resolution CT scanning of select sections was performed with NETL’s micro-CT scanner. The combination of methods used provides a multiscale analysis of the core; the resulting macro and micro descriptions are relevant to many subsurface energy related examinations traditionally performed at NETL.

58 GEOSCIENCES↗
DOE OSTI2022

Accelerated radiation transport modeling techniques for pencil beam computed tomography using gamma rays

Monte Carlo radiation transport modeling studies were performed for a compact, and high-resolution gamma-ray computed tomography system designed for imaging irradiated nuclear fuel. The system comprises a 60 Co source – chosen for its highly penetrating 1173 keV and 1332 keV gamma rays – a pair of high-aspect-ratio pencil beam collimators, and an inorganic scintillator detector. Here two acceleration methods are proposed to rapidly model a transmission type gamma-ray tomography system. The first, a variance reduction technique, is based on performing Monte Carlo simulations with a monodirectionally-biased source, sampled from a characteristic sub-volume of the full source volume. The second acceleration method is based on the deterministic calculations using the Beer–Lambert law and detector response characteristics. Comparison of simulations using acceleration approaches with analog simulations of the fully isotropic, full-volume equivalent, show that the Monte Carlo variance reduction technique gives quantitatively accurate predictions for large collimator aspect ratios while the deterministic calculations are semi-quantitative but converge close to the correct result as the collimator aspect ratio increases. As such, these techniques can be used to reduce the computational cost in generating simulated radiographs and tomographs by several orders of magnitude. Experimental validation efforts are currently underway and will be demonstrated in future work.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Porous Iron Electrodes Reduce Energy Consumption During Electrocoagulation of a Virus Surrogate: Insights into Performance Enhancements Using Three-Dimensional Neutron Computed Tomography

Electrocoagulation has attracted significant attention as an alternative to conventional chemical coagulation because it is capable of removing a wide range of contaminants and has several potential advantages. In contrast to most electrocoagulation research that has been performed with nonporous electrodes, in this study, we demonstrate energy-efficient iron electrocoagulation using porous electrodes. In batch operation, investigation of the external pore structures through optical microscopy suggested that a low porosity electrode with sparse connection between pores may lead to mechanical failure of the pore network during electrolysis, whereas a high porosity electrode is vulnerable to pore clogging. Electrodes with intermediate porosity, instead, only suffered a moderate surface deposition, leading to electrical energy savings of 21% and 36% in terms of electrocoagulant delivery and unit log virus reduction, respectively. Neutron computed tomography revealed the critical role of electrode porosity in utilizing the electrode’s internal surface for electrodissolution and effective delivery of electrocoagulant to the bulk. Energy savings of up to 88% in short-term operation were obtained with porous electrodes in a continuous flow-through system. Further investigation on the impact of current density and porosity in long-term operation is desired as well as the capital cost of porous electrodes.

42 ENGINEERING↗
DOE OSTI2023

Micro X-ray computed tomography examination of mini plate fuel with hot isostatic pressed aluminum cladding

In order to minimize proliferation risks and improve security of nuclear material, the United States high performance research and test reactors (USHPRR) program is tasked with converting nuclear reactors that are fueled with highly enriched uranium (HEU) fuels to operate with low-enriched uranium (LEU) nuclear fuels. One favorable LEU fuel configuration is plate fuel with a metallic uranium-molybdenum foil clad within an aluminum alloy (AA 6061). In this fuel, the aluminum cladding is bonded with a hot isostatic pressing (HIP) method to seal the cladding around the fuel meat. However, the HIP process parameters influence the cladding performance, as a defective or incomplete bond can cause a pathway for corrosion. Micro X-ray computed tomography (XCT), a nondestructive technique that provides volumetric imaging, can be applied to inspect fuel plate cladding at the engineering scale. In this work, XCT methodology was developed and successfully utilized to not only observe the bond line of unirradiated mini fuel plates, but to also identify subsurface abnormalities in the plates’ cladding. Importantly, in future work, this technique could be applied to fuel plates, pre- and post-irradiation, to quantify irradiation effects on cladding defects and bond line integrity.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Ultrasonic Testing (UT) and Computed Tomography (CT) Comparative Scanning of Proposed Additive Manufacturing Reference Standard

This report presents qualitative results of ultrasonic full matrix capture/total focusing method (FMC/TFM) scanning of two series of blocks, additively manufactured by powder bed fusion, containing a variety of internal features and structures that would not be achievable by conventional manufacturing techniques. The purpose of the first series of additively manufactured (AM) blocks was to explore the possibility of building calibration blocks for FMC/TFM ultrasonic testing (UT). It was confirmed that AM is a suitable candidate for generation of unusual and novel reflector forms, such as rotating slots, purposely embedded voids, and tapering holes, and that FMC/TFM was very capable of characterizing them. The intended use of the second series of AM blocks was as UT reference blocks to characterize the AM process quality or the interrogating UT technique. The larger block in this series was scanned from multiple faces, using multiple UT methods (conventional UT and FMC/TFM) and X-ray computed tomography for comparative purposes. The performance of each method was quantified by a metric corresponding to the detection limit of each feature, and the quantitative results are discussed.

36 MATERIALS SCIENCE↗