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Bond Line Thickness Estimation in Composite Structures Using Multiple Inspection Techniques

Imaging and other nondestructive evaluation techniques are commonly used for material characterization and defect recognition in safety critical aerospace applications, with data fusion providing the framework for uncertainty quantification in these contexts. Most commonly, forward physics-based modeling predicts the response conditioned on material properties and defect assumptions, and probabilistic methods are used to infer the hidden state of subject of the inspection from a combination of prior information, likelihoods, and inspection data. In this paper Bayesian methods are used to estimate bond thickness in lap joints comprised of aluminum adherends using a combination of infrared thermography, digital radiography, and ultrasound. The accuracy of the fused estimates are validated against data generated from synthetic specimens, and by comparison against high resolution X-ray computed tomography inspections of built specimens.

thermal nondestructive evaluation↗
DOE OSTI2024

Go with the Radflow: Thermal radiation experiments in the high energy-density regime [Slides]

Los Alamos National Laboratory is a nuclear weapons laboratory supporting our nation's defense. In support of the mission is a high energy-density physics program in which we design and execute experiments to study radiation-hydrodynamics phenomena and improve the predictive capability of our large-scale multi-physics software codes on our supercomputers. The Radflow Project is maturing a unique spectroscopic measurement that yields a spatially dependent supersonic radiation wavefront profile. The spectroscopic measurement is much more constraining than the typically used radiography, which measures the density changes due to the shock as the radiation wave goes subsonic. Recently, the spectroscopic measurement has been applied to advanced targets with a detailed heterogeneity representing a single realization of a stochastic medium. The Radflow Project also conducts opacity experiments to explain the current conundrum of the experimental iron opacity differing from theory, which is important in modeling the sun. More than that, though, we need to be able to answer these science questions and be able to validate our theory and codes.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2021

First Experiments and Radiographs on the MegaJOuLe Neutron Imaging Radiography (MJOLNIR) Dense Plasma Focus

We report a dense plasma focus (DPF) is a relatively compact coaxial plasma gun, which completes its discharge as a Z-pinch. These devices are designed to operate at a variety of scales to produce short (<100 ns) pulses of ions, X-rays, and/or neutrons. LLNL recently constructed and brought into operation a new device, the MegaJOuLe Neutron Imaging Radiography (MJOLNIR) DPF, which is designed for radiography and high-yield operations. This device has been commissioned and has achieved neutron yields of up to 3.8E11 neutrons/pulse at 2.5-MA peak current while operating at up to 1 MJ of stored energy in its original pulsed power configuration. MJOLNIR is equipped with a wide range of diagnostics, including nuclear activation detectors, neutron time-of-flight (nToF) detectors, a fast-framing camera, optical light gates, and a time-gated neutron and X-ray imager. LLNL also runs unique particle-in-cell (PIC) simulations of DPF discharges in the Chicago code and has gained significant insight into the various physical factors that influence neutron yield. MJOLNIR is one of the first DPFs whose design and continual upgrades are heavily influenced by model predictions. In this article, we describe insights from modeling, device operation, and recent results. Comparisons between modeling predictions and measurements, as well as X-ray and neutron images are presented.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2022

Investigation of resistive magnetic field generation by intense proton beams in dense plasmas

Current and future applications of intense proton sources abound, including radiography, cancer therapy, warm dense matter generation, and inertial confinement fusion. With increasingly efficient acceleration and focusing mechanisms, proton current densities may soon approach and exceed 10 10 A/cm 2 , e.g., via intense laser drivers. Simulations have previously shown that in this current density regime, beam-induced field generation plays a significant role in beam transport through dense plasmas. Here, we present a theoretical model for the generation of resistive magnetic fields by intense proton beam transport through solid density plasmas. The theoretical evolution of the magnetic field profile is calculated using an analytic model for aluminum resistivity, heat capacity, and stopping power, applicable from cold matter to hot plasma. The effects of various beam and material parameters on the field are investigated and explained for both monoenergetic and Maxwellian proton beams. For a proton beam with Maxwellian temperature 5 MeV and total energy 10 J, the model calculates resistive magnetic fields up to 150 T in aluminum. In conclusion, the calculated field profiles from several beam cases are compared with 2D hybrid particle-in-cell simulations, with good agreement found in magnitude and time scale.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2026

In-situ observation of calcium chloride hexahydrate phase separation via neutron imaging

Inorganic salt hydrate offers a low-cost thermal energy storage solution with high energy density, but phase separation during thermal cycling poses a significant challenge, leading to irreversible performance degradation. In this research, neutron radiography was used to investigate phase separation in calcium chloride hexahydrate (CaCl₂·6H₂O, CCH) during thermal cycling to track its gradual accumulation into calcium chloride tetrahydrate (CaCl₂·4H₂O, CC4). Through in-situ visualization, phase separation and CC4 sedimentation were observed to occur during the cooling phase between 301.40 K and 304.80 K. CC4 accumulated linearly to 7.99 wt% after 10 thermal cycles. Crystallization and multi-cycle conversion models were developed to validate neutron imaging results of CC4 formation. The predicted CC4 content after 10 thermal cycles closely aligned with experimental observations. Neutron imaging offers a novel approach to investigate salt hydrate phase change materials (PCMs). It enables in-situ visualization of sub-hydrate (CC4) formation from original hydrate (CCH) in metastable phase change range (between 301.40 ± 0.66 K and 304.80 ± 0.60 K). Thereby, it provides a new insight of understanding the basis of phase separation mechanism and paves the way for future research of improving PCM thermal cycling performance.

Li, Yucen [The University of Tennessee, Knoxville]↗
DOE OSTI2024

Phase retrieval for refraction-enhanced x-ray radiography using a deep neural network

X-ray refraction-enhanced radiography (RER) or phase contrast imaging is widely used to study internal discontinuities within materials. The resulting radiograph captures both the decrease in intensity caused by material absorption along the x-ray path, as well as the phase shift, which is highly sensitive to gradients in density. A significant challenge lies in effectively analyzing the radiographs to decouple the intensity and phase information and accurately ascertain the density profile. Conventional algorithms often yield ambiguous and unrealistic results due to difficulties in including physical constraints and other relevant information. We have developed an algorithm that uses a deep neural network to address these issues and applied it to extract the detailed density profile from an experimental RER. To generalize the applicability of our algorithm, we have developed a technique that quantitatively evaluates the complexity of the phase retrieval process based on the characteristics of the sample and the configuration of the experiment. Accordingly, this evaluation aids in the selection of the neural network architecture for each specific case. Beyond RER, the model has potential applications for other diagnostics where phase retrieval analysis is required.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

Measuring characteristic differences between high- and low-performing discharges on the MegaJOuLe Neutron Imaging Radiography (MJOLNIR) DPF

A dense plasma focus (DPF) is a compact coaxial plasma gun, which completes its discharge as a Z-pinch, producing short (<100 ns) pulses of ions, x rays, and/or neutrons. Lawrence Livermore National Laboratory recently constructed and began operating a new device, the MJOLNIR (MegaJOuLe Neutron Imaging Radiography) DPF, which is designed for single-pulse flash neutron radiography. This device has achieved neutron yields of up to 4.1×10 11 neutrons/pulse at 3.3 MA peak current, and higher-current commissioning is under way. Like most DPFs, MJOLNIR exhibits variable yields in some configurations. Here, we present evidence of the role of parasitic current paths within the gun in stochastically influencing the yield. First through “conditioning shots,” where new hardware has been introduced, we show that increased run-down and run-in speeds correlate with higher yields. These observations are consistent with current being delivered to the electrodes but not to the main plasma sheath, degrading the implosion-driving force. Once nominal conditions are established, we correlate low-performing discharges with smaller current dip and associated voltage spike for a fixed machine configuration. A snow-plow model is able to recreate small-magnitude current dips through the introduction of a parasitic current path, and particle-in-cell simulations establish how parasitic current paths lower the ion beam energy available to produce neutrons. Finally, we observe an increased likelihood of shots with low yield and smaller current dip with increasing fill pressure.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Laboratory-Based Micro-X-ray Computed Tomography of Energy Materials at Idaho National Laboratory

Abstract The Idaho National Laboratory (INL) has implemented laboratory-based micro-X-ray computed tomography in a laboratory equipped for the examination of highly radioactive samples. This capability provides nondestructive three-dimensional volumetric information on samples to inform subsequent traditional destructive examinations as well as real-world inputs for high-fidelity scientific modeling. Samples can be imaged with spatial resolutions ranging from several hundred nm/voxel up to ~ 100 µm/voxel. The best usable spatial resolution achieved to date is 384 nm/voxel with this instrument, while the highest radiological dose rate of a sample imaged is ~ 60 R/h β/γ on contact. Advanced data analysis, including custom tomographic reconstruction and segmentation methods, have also been developed to support this capability. In addition to traditional digital X-ray radiography and tomography, this instrument is also able to visualize in situ tensile and compression testing as well as perform diffraction contrast tomography. This work describes the X-ray computed tomography post-irradiation examination capabilities at INL, as well as detailing a variety of applications this instrument has examined.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Simulation tools, first results and experimental status of the MURAVES experiment

The MUon RAdiography of VESuvius (MURAVES) project aims at the study of Mt. Vesuvius, an active and hazardous volcano near Naples, Italy, with the use of muons freely and abundantly produced by cosmic rays. In particular, the MURAVES experiment intends to perform muographic imaging of the internal structure of the summit of Mt. Vesuvius. The challenging measurement of the rock density distribution in its summit by muography, in conjunction with data from other geophysical techniques, can help model possible eruption dynamics. The MURAVES apparatus consists of an array of three independent and identical muon trackers, with a total sensitive area of 3 square meters. In each tracker, a sequence of 4 XY tracking planes made of plastic scintillators is complemented by a 60 cm thick lead wall inserted between the two downstream planes to improve rejection of background from low energy muons. The apparatus is currently acquiring data. This paper presents preliminary results from the analysis of the first data samples acquired with trackers pointing towards Mt. Vesuvius, including the first relative measurement of the density projection of two flanks of the volcano at three different altitudes; we also present the workflow of the simulation chain of the MURAVES experiment and its ongoing developments.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2025

Probing the Mechanism of Selective Phosphate Adsorption from Wastewater Using Aqueous and Synchrotron X-ray Characterization

Ion exchange shows promise for recovering phosphate from wastewater as value-added products, but requires high phosphate selectivity to compete with conventional treatment. Hybrid anion exchange (HAIX) resins, which contain non-selective basic functional groups and selective iron oxide nanoparticles (FeOnp), can effectively remove phosphate from wastewater. However, knowledge gaps remain regarding the mechanisms of phosphate selectivity and influence of competing ions, hindering needed efforts to model adsorption dynamics and design scalable adsorption processes for varying wastewaters. To address these gaps, we integrated aqueous-phase adsorption analysis with solid-phase, synchrotron-based X-ray characterization; this integration facilitated elucidation of the distribution and speciation of iron, phosphate, and competing anions on HAIX resins. We compared a quaternary ammonium-functionalized HAIX resin (SBA) to a tertiary amine version (WBA) to determine the role of functional groups. X-ray radiography revealed differences in FeOnp speciation (goethite vs. ferrihydrite) and distribution (peripheral vs. homogeneous) between the resins, resulting in varied phosphate affinity and intraparticle diffusion resistance. Using micro-X-ray fluorescence (μ-XRF) and micro-X-ray absorption near-edge structure (μ-XANES) spectroscopy, we identified differences in where and how phosphate binds across resin types and wastewaters. Across wastewater compositions, FeOnp sites in WBA contribute more to phosphate adsorption than in SBA, possibly due to variations in Fe distribution and speciation. Phosphate adsorption densities calculated from quantitative μ-XRF maps matched those from aqueous analysis, demonstrating the effectiveness of this integrated approach. Altogether, results demonstrate the use of synchrotron-based X-ray characterization for investigating adsorption mechanisms and advance HAIX as a phosphate recovery technology from complex wastewaters.

Nutrient recovery↗
DOE OSTI2025

Characterizing the Experiment for Calibration with Uranium (Excalibur) neutron source for use in warhead verification

Neutron sources can play a variety of roles in warhead verification. For transmission radiography, a source of directed high energy neutrons is required, while for applications to detect fissile isotopes, sub-MeV neutrons are preferred. The Excalibur (Experiment for Calibration with Uranium) neutron source has been built and used in a variety of verification-related experiments. Excalibur is based on a commercial deuterium-tritium neutron generator specified and measured to be capable of producing 14 MeV neutrons at rates of up to 8.2 × 10 8 neutrons/s. Here, the generator is enclosed in a carbon-steel 32" diameter, 23.62" high carbon-steel cylinder that moderates the mean neutron energy to under 500 keV. This, in turn, is encased in 5%-borated polyethylene such that the entire assembly is a 48" x 48" box that is 30" tall. For radiographic applications, a narrow, tapered channel in the steel and polyethylene allows 14 MeV neutrons to stream directly from the generator to a test object. Its collimating capability is demonstrated by measuring the neutron flux profile. In the moderated mode of operation, the generator is fully enclosed in the steel, but a large section of the polyethylene is removed, providing a flux of sub-MeV neutrons from a wide range of angles. Neutron angular and spectral measurements using both a nested neutron spectrometer and a commercial liquid scintillator coupled with a 3 He detector show the expected softer neutron spectrum in moderated mode in good agreement with MCNP6 calculations. The gamma-ray spectrum from Excalibur is also in good agreement with MCNP modeling. Based on these findings, the future application of Excalibur in its two configurations is discussed.

Fissile material detection↗
NASA NTRS2017

Fully Coupled Aero-Thermochemical-Elastic Simulations of an Eroding Graphite Nozzle

A multiphysics simulation capability has been developed that incorporates mutual interactions between aerodynamics, structural response from aero/thermal loading, ablation/pyrolysis, heating, and surface-to-surface radiation to perform high-fidelity, fully coupled aerothermoelastic ablation simulations, which to date had been unattainable. The multiphysics framework couples CHAR (a 3-D implicit charring ablator solver), Loci/CHEM (a computational fluid dynamics solver for high-speed chemically reacting flows), and Abaqus (a nonlinear structural dynamics solver) to create a fully coupled aerothermoelastic charring ablative solver. The solvers are tightly coupled in a fully integrated fashion to resolve the effects of the ablation pyrolysis and charring process and chemistry products upon the flow field, the changes in surface geometry due to recession upon the flow field, and thermal-structural analysis of the body from the induced aerodynamic heating from the flow field. The multiphysics framework was successfully demonstrated on a solid rocket motor graphite nozzle erosion application. Comparisons were made with available experimental data that measured the throat erosion during the motor firing. The erosion data is well characterized, as the test rig was equipped with a windowed nozzle section for real-time X-ray radiography diagnostics of the instantaneous throat variations for deducing the instantaneous erosion rates. The nozzle initially undergoes a nozzle contraction due to thermal expansion before ablation effects are able to widen the throat. A series of parameters studies were conducted using the coupled simulation capability to determine the sensitivity of the nozzle erosion to different parameters. The parameter studies included the shape of the nozzle throat (flat versus rounded), the material properties, the effect of the choice of turbulence model, and the inclusion or exclusion of the mechanical thermal expansion. Overall, the predicted results match the experiment very well, and the predictions were able to bound the data within acceptable limits.

Blades, E. L.↗
DOE OSTI2022

Sensor fusion of pyrometry and acoustic measurements for localized keyhole pore identification in laser powder bed fusion

We report in-situ process monitoring as an aid to part qualification for laser powder-bed fusion (L-PBF) technology is a topic of increasing interest to the additive manufacturing community. In this work, airborne acoustic and inline pyrometry measurements were recorded simultaneously with the laser position. X-ray radiography imaging was used to spatio-temporally register keyhole pore locations to the pyrometry and acoustic signals, enabling binary labeling of data partitions based on pore formation. These labeled partitions were subsequently featurized using a highly comparative time-series analysis toolbox. Acoustic data was found to be much more effective than the pyrometry data for keyhole pore identification. However, when the information contained in both sensing modalities was combined in a sensor fusion strategy, the error rates of the top performing models were significantly reduced.

36 MATERIALS SCIENCE↗
DOE OSTI2022

The MURAVES muon telescope: a low power consumption muon tracker for muon radiography applications

Muon Radiography or muography is based on the measurement of the absorption or scattering of cosmic muons, as they pass through the interior of large scale bodies, In particular, absorption muography has been applied to investigate the presence of hidden cavities inside the pyramids or underground, as well as the interior of volcanoes’ edifices. The MURAVES project has the challenging aim of investigating the density distribution inside the summit of Mt. Vesuvius. The information, together with that coming from gravimetric measurements, is useful as input to models, to predict how an eruption may develop. The MURAVES apparatus is a robust and low power consumption muon telescope consisting of an array of three identical and independent muon trackers, which provide in a modular way a total sensitive area of three square meters. Each tracker consists of four doublets of planes of plastic scintillator bars with orthogonal orientation, optically coupled to Silicon photomultipliers for the readout of the signal. The muon telescope has been installed on the slope of the volcano and has collected a first set of data, which are being analyzed.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2021

Experimental validation of shock propagation through a foam with engineered macro-pores

The engineered macro-pore foam provides a new way to study thermonuclear burn physics by utilizing capsules containing deuterated (D) foam and filling tritium (T) gas in the engineered macro-pores. The implosion of a thermonuclear capsule filled with an engineered macro-pore foam will be complex due to the interaction of a shock wave with the engineered macro-pores. It is our goal to quantify how substantially complex foam structures affect the shape of shock and bulk shock speed. A cylinder-shape shock tube experiment has been designed and performed at the Omega Laser Facility. In order to examine how a foam structure will affect shock propagation, we performed several tests varying (1) engineered macro-pore size, (2) average foam density, and (3) with/without neopentane (C 5 H 12 ) gas. X-ray radiographic data indicate that shock speed through engineered macro-pore foams depends strongly on average foam density and less on pore size. In this work, experimental shock propagation data helped guide two numerical simulation approaches: (1) a 2D simulation with homogenizing foams rather than explicitly simulating engineered macro-pores and (2) a 2D toroidal-pore approximation adopting a toroidal-tube geometry to model engineered macro-pores.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

Comprehensive Review of DPF-based Flash Neutron Radiography Viability

MJOLNIR (MegaJOule Neutron Imaging Radiography) is a Dense Plasma Focus (DPF) being developed by LLNL as a prototype to assess the viability of a DPF as a flash neutron radiography source. To date, MJOLNIR has discharged up to 1.3 MJ of stored energy into a deuterium plasma load and achieved yields up to 1.2 × 10 12 neutrons per discharge. The MJOLNIR pulse length already meets the preliminary requirements for flash neutron radiography and we demonstrate in this report plausible paths forward to meet the yield requirement in a deuterium plasma. MJOLNIR’s neutron spot size has been characterized to be a factor of two greater than radiography requirements and presents the greatest challenge. A path forward to sufficiently shrinking spot size is outlined in this report, using a combination of gas dopants and a smaller anode implosion radius. A DPF is a plasma device with coaxial electrodes whose discharge ends with a stagnated hot and dense plasma column on-axis, at the tip of the central anode. Inside the MJOLNIR DPF plasma column, both thermal and beam target processes generate neutrons. To understand the underlying physics of neutron generation inside the DPF, we model the experiment using a combination of kinetic, fluid, and reduced-order models we have been developing for over ten years at LLNL. Our numerical tools are also pivotal to charting the path forward because they allow us to numerically test out which modifications would improve the DPF’s characteristic output.

42 ENGINEERING↗
NASA NTRS2020

Radiography in High Mass X-Ray Binaries: Micro-Structure of the Stellar Wind Through Variability of the Column Density

Context. In high mass X-ray binaries, an accreting compact object orbits a high mass star, which loses mass through a dense and in homogeneous wind. Aims. Using the compact object as an X-ray backlight, the time variability of the absorbing column density in the wind can be exploited in order to shed light on the micro-structure of the wind and obtain unbiased stellar mass-loss rates for high mass stars. Methods. We developed a simplified representation of the stellar wind where all the matter is gathered in spherical “clumps” that are radially advected away from the star. This model enables us to explore the connections between the stochastic properties of the wind and the variability of the column density for a comprehensive set of parameters related to the orbit and to the wind micro-structure, such as the size of the clumps and their individual mass. In particular, we focus on the evolution with the orbital phase of the standard deviation of the column density and of the characteristic duration of enhanced absorption episodes. Using the porosity length, we derive analytical predictions and compare them to the standard deviations and coherence time scales that were obtained. Results. We identified the favorable systems and orbital phases to determine the wind micro-structure. The coherence time scale of the column density is shown to be the self-crossing time of a single clump in front of the compact object. We thus provide a procedure to get accurate measurements of the size and of the mass of the clumps, purely based on the observable time variability of the column density. Conclusions. The coherence time scale grants direct access to the size of the clumps, while their mass can be deduced separately from the amplitude of the variability. We further show how monitoring the variability at superior conjunctions can probe the onset of the clump-forming region above the stellar photosphere. If the high column density variations in some high mass X-ray binaries are due to unaccreted clumps which are passing by the line-of-sight, this would require high mass clumps to reproduce the observed peak-to-peak amplitude and coherence time scales. These clump properties are marginally compatible with the ones derived from radiative-hydrodynamics simulations. Alternatively, the following components could contribute to the variability of the column density: larger orbital scale structures produced by a mechanism that has yet to be identified or a dense environment in the immediate vicinity of the accretor, such as an accretion disk, an outflow, or a spherical shell surrounding the magnetosphere of the accreting neutron star.

stars: mass loss↗
NASA NTRS2007

Experimental Design for the Evaluation of Detection Techniques of Hidden Corrosion Beneath the Thermal Protective System of the Space Shuttle Orbiter

The detection of corrosion beneath Space Shuttle Orbiter thermal protective system is traditionally accomplished by removing the Reusable Surface Insulation tiles and performing a visual inspection of the aluminum substrate and corrosion protection system. This process is time consuming and has the potential to damage high cost tiles. To evaluate non-intrusive NDE methods, a Proof of Concept (PoC) experiment was designed and test panels were manufactured. The objective of the test plan was three-fold: establish the ability to detect corrosion hidden from view by tiles; determine the key factor affecting detectability; roughly quantify the detection threshold. The plan consisted of artificially inducing dimensionally controlled corrosion spots in two panels and rebonding tile over the spots to model the thermal protective system of the orbiter. The corrosion spot diameter ranged from 0.100" to 0.600" inches and the depth ranged from 0.003" to 0.020". One panel consisted of a complete factorial array of corrosion spots with and without tile coverage. The second panel consisted of randomized factorial points replicated and hidden by tile. Conventional methods such as ultrasonics, infrared, eddy current and microwave methods have shortcomings. Ultrasonics and IR cannot sufficiently penetrate the tiles, while eddy current and microwaves have inadequate resolution. As such, the panels were interrogated using Backscatter Radiography and Terahertz Imaging. The terahertz system successfully detected artificially induced corrosion spots under orbiter tile and functional testing is in-work in preparation for implementation.

Kemmerer, Catherine C.↗