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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 163 records · Page 9

Multimodal Data Fusion via Entropy Minimization

The use of gradient-based data-driven models to solve a range of real-world remote sensing problems can in practice be limited by the uniformity of available data. Use of data from disparate sensor types, resolutions, and qualities typically requires compromises based on assumptions that are made prior to model training and may not necessarily be optimal given over-arching objectives. For example, while deep neural networks (NNs) are state-of-the-art in a variety of target detection problems, training them typically requires either limiting the training data to a subset over which uniformity can be enforced or training independent models which subsequently require additional score fusion. The method we introduce here seeks to leverage the benefits of both approaches by allowing correlated inputs from different data sources to co-influence preferred model solutions, while maintaining flexibility over missing and mismatching data. In this work we propose a new data fusion technique for gradient updated models based on entropy minimization and experimentally validate it on a hyperspectral target detection dataset. We demonstrate superior performance compared to currently available techniques using a range of realistic data scenarios, where available data has limited spacial overlap and resolution.

97 MATHEMATICS AND COMPUTING↗

Magnetostrictive materials for enhanced sensors and electronic components

Magnetostriction is a property of magnetic materials that causes them to change their shape or dimensions proportional to their magnetization. Low-cost, mechanically robust magnetostrictive sensors would be valuable for a wide range of applications across the DOE and national security mission space, such as monitoring the internal conditions of pipelines, rapidly detecting high-impedance faults in power lines (e.g. trees touching power lines), or enhancing implantable systems for the human body. Dilute doping (<1 at.%) of rare earth elements (REE) has been shown to amplify the magnetostriction. Furthermore, alloy processing by rapid cooling from high temperature tends to result in texturing and therefore greater magnetostriction values, which bodes well for developing advanced manufacturing approaches significantly less expensive than single crystal growth. The goal of this effort was to develop robust, low-cost magnetostrictive materials compatible with advanced manufacturing techniques to exploit the rapid cooling of these approaches while retaining the ability to produce fully dense structures. To be useful as a sensor or actuator the coercivity of the material needs to be minimized so that there is minimal magnetic hysteresis. Employing a small scale laser powder bed fusion (L-PBF) system, specimens of Fe-Ga-Ce were built from alloy powder which had a magnetostriction of 289 ppm along the build direction and 197 ppm perpendicular to the build direction. These values are not far from the 310-350 ppm observed in single crystals of Fe-Ga. The results of the series of samples run suggest this is a very promising route for REE doping to higher levels, especially if the powders can be produced using far from equilibrium approaches such as ultrasonic atomization. The promising results from applying additive manufacturing techniques to these materials, particularly the inexpensive Fe-Al system, has potential for inexpensive high-performing magnetostrictive parts producible at large scales for low-cost sensors.

36 MATERIALS SCIENCE↗

A deep learning framework for layer-wise porosity prediction in metal powder bed fusion using thermal signatures

Abstract Part quality manufactured by the laser powder bed fusion process is significantly affected by porosity. Existing works of process–property relationships for porosity prediction require many experiments or computationally expensive simulations without considering environmental variations. While efforts that adopt real-time monitoring sensors can only detect porosity after its occurrence rather than predicting it ahead of time. In this study, a novel porosity detection-prediction framework is proposed based on deep learning that predicts porosity in the next layer based on thermal signatures of the previous layers. The proposed framework is validated in terms of its ability to accurately predict lack of fusion porosity using computerized tomography (CT) scans, which achieves a F1-score of 0.75. The framework presented in this work can be effectively applied to quality control in additive manufacturing. As a function of the predicted porosity positions, laser process parameters in the next layer can be adjusted to avoid more part porosity in the future or the existing porosity could be filled. If the predicted part porosity is not acceptable regardless of laser parameters, the building process can be stopped to minimize the loss.

42 ENGINEERING↗

NIF-TAS Miniature Calibration Station

“On Aug. 8, 2021, an experiment at Lawrence Livermore National Laboratory’s (LLNL’s) National Ignition Facility (NIF) made a significant step toward ignition, achieving a yield of more than 1.3 megajoules (MJ). This advancement puts researchers at the threshold of fusion ignition, an important goal of the NIF, and opens access to a new experimental regime.” NIF experiments are conducted by symmetrically focusing 192 laser beams from NIF (three football fields in length) into the Target Chamber (10-meter diameter sphere) onto a target 2mm in size. The reaction produces a hot spot the diameter of a human hair, generating more than 10 quadrillion watts of fusion power for 100 trillionths of a second. These high pressures and temperatures created by the NIF have only been seen on the surface of the sun. To achieve fusion ignition, the target must be compressed to high pressures and temperatures, which requires symmetric compression. This symmetry requires precise alignment of the laser beams to the target. To achieve this precise symmetry a Target Alignment System (TAS) was developed to aid in aligning the beams to the target. The accomplishment on Aug 8 th could not have been accomplished without the TAS. TAS has proven to be a critical contributor to the success of NIF experiments. Each TAS is composed of several Charge Couple Device (CCD) sensors and various support electronics. Unfortunately, these CCDs are no longer available in industry as they have become outdated and obsolete. There is a limited amount of spare CCDs in the facility. As the NIF continues to increase its energy output of its fusion ignition shot experiments (heigh yield shots), more neutrons are being emitted from the Target Chamber. These neutrons are very damaging to the TAS electronics and its sensors, thus degrading and reducing its life expectancy dramatically. The increase of neutrons exceeds the damage threshold of the CCDs. This would increase the demand for more frequent TAS refurbishments and calibrations. The increase in resources to perform these refurbishments and calibrations would not be sustainable. In efforts to prolong the life of each TAS system it was determined that the TAS should be removed for every High Yield Shot and then reinstalled. The high precision fully calibrated TAS can easily be knocked out of alignment during these installs and reinstall exchanges and being transported in and out of the NIF. The Miniature Calibration Station System was developed to verify that the critical calibration parameters have been preserved during every TAS exchange. The Miniature Calibration Station System (Mini-Cal) would need to be a scaled down (in size and scope), portable version of the offline TAS calibration station to verify the critical TAS parameters are still within tolerances.

42 ENGINEERING↗

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↗

Accelerating Additive Manufacturing Process Design for Energy Conversion Materials using In-situ Sensing and Machine Learning

One promising candidate for manufacturing of the bismuth Telluride thermoelectric legs is laser powder bed fusion (LPBF) additive Manufacturing (AM). AM processing parameters highly influence the material properties, however current processing parameter development methods in AM are costly and time consuming. In-situ sensors allow for the capture of physically relevant process information on a layer-by-layer basis and will be used to aide process development. To optimize the AM process for the best thermoelectric performance, process variables, in-situ process sensor data and ex-situ material characterization data are collected. Several different interpretable machine learning (ML) approaches are used, and the performance of each method are assessed. Significant input process variables include laser focus, hatch spacing and laser power. The best performing models are used to determine the manufacturing parameters that maximize the power factor. AM of bismuth telluride material provides the ability to create complex geometries enabling more efficient energy conversion.

30 DIRECT ENERGY CONVERSION↗

FuSED Users Manual, 5.24

The Fusion of Simulation, Experiment, and Data (FuSED) team provides a set of tools for solving inverse problems in structural dynamics and thermal physics, and also sensor placement optimization via Optimal Experimental Design (OED). These methods are used for designing experiments, model calibration, and verification/validation analysis of systems. This document provides a user’s guide to the input for the three apps that are supported for these methods. Details of input specifications, output options, and optimization parameters are included.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

Sensor selection and tool wear prediction with data‐driven models for precision machining

Abstract Estimation of tool wear in precision machining is vital in the traditional subtractive machining industry to reduce processing cost, improve manufacturing efficiency and product quality. In this vein, fusion of time and frequency‐domain features of commonly sensed signals can provide an early indication of tool wear and improve its prediction accuracy for prognostics and health management. This paper presents a data‐driven methodology and a complete tool chain for the inference of precision machining tool wear from fused machine measurements, such as cutting force, power, audio and vibration signals, and quantify the usefulness of each measurement. Indicators of tool wear are extracted from time‐domain signal statistics, frequency‐domain analysis, and time‐frequency domain analysis. Correlation coefficients between the extracted features (indicators) and the tool wear are used to select the most informative features. Principal Component Analysis and Partial Least‐Squares are used to reduce the dimensionality of the feature space. Regression models, including linear regression, support vector regression, Decision tree regression, neural network regression and Gaussian process regression, are used to predict the tool wear using data from a Haas milling machine performing spiral boss face milling. The performance of the regression models based on subsets of sensors validates the preliminary estimates about the saliency of the sensors. The experimental results show that the proposed methods can predict the machine tool wear precisely, with readily available sensor measurements. Neural network and Gaussian process regression were able to achieve good estimates of tool wear at different machine operating conditions. The most informative signal in predicting tool wear was shown to be the vibration signal. Time‐frequency domain features were the most informative features among the combination of features of three domains. In addition, using partial least squares components extracted from the original features of signals led to higher prediction accuracy.

Han, Seulki↗

Analytic solutions for Asay foil trajectories with implications for ejecta source models and mass measurements

We consider the trajectory of an Asay foil ejecta diagnostic for scenarios where ejecta are produced at a singly shocked planar surface and fly ballistically through a perfect vacuum to the sensor. We do so by building upon a previously established mathematical framework derived for the analytic study of stationary sensors. First, we derive the momentum conservation equation for the problem, in a form amenable to accelerating sensors, in terms of a generic ejecta source model. The result is an integrodifferential equation of motion for the foil trajectory. This equation yields an easily calculable closed-form implicit solution for the foil trajectory in instant-production scenarios. From there, we derive a boundary condition that particle velocity distributions must satisfy if their associated foil trajectories are to exhibit a smooth initial acceleration, as occurs in some experiments. This condition is identical to one derived previously from a consideration of piezoelectric voltage data obtained in similar experiments. We also compare techniques for inferring accumulated ejecta masses from foil trajectories, first by deriving the exact solution, and then by quantifying the error imposed by a frequently used approximate solution (both subject to the assumption of instantaneous ejecta production). Finally, we examine the common practice of presenting inferred cumulative ejecta masses as a function of implied ejecta velocity, establishing the conditions under which this methodology is most meaningful.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Fiber-Optic Silicon Fabry-Perot Interferometric Bolometer: The Influence of Mechanical Vibration and Magnetic Field

Plasma radiation plays an important role in the operation and control of magnetic confinement fusion and is typically measured by bolometers. Here, we study the influence of mechanical vibration and magnetic field, which are typically present in magnetic confinement fusion devices, on the performance of a fiber-optic bolometer (FOB) based on silicon Fabry-Perot interferometer (FPI) demodulated by a scanning diode laser. It is found that both the vibration and magnetic field could cause large noise due to the birefringence of the silicon FPI. To mitigate the birefringence effects, we demonstrated two effective methods: polarization maintaining FOB and polarization scrambling. We show that two methods can be effective in mitigating the effect caused by the sensor birefringence: (1) replacing the regular single-mode fiber in the FOB system with polarization-maintaining fiber and (2) using a polarization scrambler after the laser source. For both methods, no significant increase in the noise was observed in the vibration and magnetic field tests. Finally, our research highlights the importance of the polarization management for the FOB systems toward their practical applications in magnetic-confinement fusion systems.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Characterization of the upgraded single-line-of-sight time-resolved x-ray imager using short-pulse visible and UV lasers

The single-line-of-sight time-resolved x-ray imager (SLOS-TRXI), a fast-gated x-ray imager used for capturing x-ray self-emission in inertial confinement fusion experiments on OMEGA, has been upgraded and characterized. SLOS-TRXI combines an electron-dilation imager and a hybrid complementary metal–oxide–semiconductor (hCMOS) sensor to capture multiple gated frames on a single line of sight with a temporal resolution of ~40 ps and a spatial resolution of 10 µm. The original hCMOS sensor with four frames was replaced with a newer-generation hCMOS sensor having eight frames. Gate characterizations of both the sensor and the entire SLOS-TRXI diagnostic were performed using ~10-ps FWHM visible (2ω) and UV (4ω) short-pulse lasers, respectively. A stepped echelon was used to generate a train of five UV laser pulses having an interpulse separation of 30 ± 3 ps. Characterization results of the hCMOS gating (2.28 ± 0.02-ns FWHM on average) and a temporal resolution of the upgraded SLOS-TRXI (34 ± 4-ps FWHM on average) are presented. A temporal magnification for the electron-dilation imager between 40 and 60 was inferred from the characterization results. Furthermore, the spatial resolution of the upgraded SLOS-TRXI remains the same in light of this work.

47 OTHER INSTRUMENTATION↗

FuSED – Users Manual – (V.5.26)

The Fusion of Simulation, Experiment, and Data (FuSED) team provides a set of tools for solving inverse problems in structural dynamics (InverseSD) and thermal physics (InverseAria), a sensor placement optimization tool via Optimal Experimental Design (OED), and a decision boundary tool using SVMs (TRACE). These methods are used for designing experiments, model calibration, and verification/validation analysis of systems. This document provides a user’s guide.

97 MATHEMATICS AND COMPUTING↗

Exploring MDSplus data-acquisition software and custom devices

MDSplus is a software tool designed for data acquisition, storage, and analysis of complex scientific experiments. Over the years, MDSplus has primarily been used for data management for fusion experiments. This paper demonstrates that MDSplus can be used for a much wider variety of systems and experiments. We present a step-by-step tutorial describing how to create a simple experiment, manage the data, and analyze it using MDSplus and Python. To this end, a custom example device was developed to be used as the data source. This device was built on an open-source electronic hardware platform, and it consists of a microcontroller and two sensors. Finally, we read data from these sensors, store it in MDSplus, and use JupyterLab to visualize and process it.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

PhytoOracle: Scalable, modular phenomics data processing pipelines

As phenomics data volume and dimensionality increase due to advancements in sensor technology, there is an urgent need to develop and implement scalable data processing pipelines. Current phenomics data processing pipelines lack modularity, extensibility, and processing distribution across sensor modalities and phenotyping platforms. To address these challenges, we developed PhytoOracle (PO), a suite of modular, scalable pipelines for processing large volumes of field phenomics RGB, thermal, PSII chlorophyll fluorescence 2D images, and 3D point clouds. PhytoOracle aims to ( i ) improve data processing efficiency; ( ii ) provide an extensible, reproducible computing framework; and ( iii ) enable data fusion of multi-modal phenomics data. PhytoOracle integrates open-source distributed computing frameworks for parallel processing on high-performance computing, cloud, and local computing environments. Each pipeline component is available as a standalone container, providing transferability, extensibility, and reproducibility. The PO pipeline extracts and associates individual plant traits across sensor modalities and collection time points, representing a unique multi-system approach to addressing the genotype-phenotype gap. To date, PO supports lettuce and sorghum phenotypic trait extraction, with a goal of widening the range of supported species in the future. At the maximum number of cores tested in this study (1,024 cores), PO processing times were: 235 minutes for 9,270 RGB images (140.7 GB), 235 minutes for 9,270 thermal images (5.4 GB), and 13 minutes for 39,678 PSII images (86.2 GB). These processing times represent end-to-end processing, from raw data to fully processed numerical phenotypic trait data. Repeatability values of 0.39-0.95 (bounding area), 0.81-0.95 (axis-aligned bounding volume), 0.79-0.94 (oriented bounding volume), 0.83-0.95 (plant height), and 0.81-0.95 (number of points) were observed in Field Scanalyzer data. We also show the ability of PO to process drone data with a repeatability of 0.55-0.95 (bounding area).

59 BASIC BIOLOGICAL SCIENCES↗

A Monte Carlo technique to model performance of streak camera-based time-resolving x-ray spectrometers

A Monte Carlo technique has been developed to simulate the expected signal and the statistical noise of x-ray spectrometers that use streak cameras to achieve the time resolution required for ultrafast diagnostics of laser-generated plasmas. The technique accounts for statistics from both the photons incident on the streak camera’s photocathode and the electrons emitted by the photocathode travelling through the camera’s electron optics to the sensor. We use the technique to optimize the design of a spectrometer, which deduces the temporal history of electron temperature of the hotspot in an inertial confinement fusion implosion from its hard x-ray continuum emission spectra. The technique is general enough to be applied to any instrument using an x-ray streak camera.

Stoupin, S. (ORCID:0000000226225270)↗

Seismoacoustic Data Fusion for Ground Coupled Airwaves: a FACT Case Study for Calibration and Array Processing

This report covers an inquiry into seismoacoustic array processing using infrasound arrivals combined with resulting Ground Coupled Airwaves (GCA) that are present on collocated seismic sensors. In preparation, data calibration and denoising is completed for a seismoacoustic sensor array that was deployed at the Facility for Acceptance, Calibration, and Testing on Kirtland Airforce Base from August through September of 2021. The events of interest for this study are small, local explosive sources that lead to short duration, impulsive signals on the instruments. The goal is to determine if combining infrasound signals with the corresponding GCAs on collocated seismic sensors can be used to improve the results returned by automated signal detection and characterization (e.g., back azimuth estimates). Preparation for seismic and infrasound data involves removing the instrument response so that sensors have flat power spectra over the frequency range 0.1-10 Hz, where signal from events of interest may be detected. After instrument response removal, deployment conditions specific to this array require a retrospective noise analysis to determine station emplacement characteristics. Once all data is calibrated, a manual search is performed for possible GCA arrivals across the seismoacoustic network. These arrivals are then processed through beamforming and subsequent event identification, resulting in a catalogue of seismoacoustic GCA arrivals with corresponding back azimuth and trace velocity estimations.

47 OTHER INSTRUMENTATION↗

Monitoring and prediction of porosity in laser powder bed fusion using physics-informed meltpool signatures and machine learning

In this work we accomplished the monitoring and prediction of porosity in laser powder bed fusion (LPBF) additive manufacturing process. This objective was realized by extracting physics-informed meltpool signatures from an in-situ dual-wavelength imaging pyrometer, and subsequently, analyzing these signatures via computationally tractable machine learning approaches. Porosity in LPBF occurs despite extensive optimization of processing conditions due to stochastic causes. Hence, it is essential to continually monitor the process with in-situ sensors for detecting and mitigating incipient pore formation. In this work a tall cuboid-shaped part (10 mm × 10 mm × 137 mm, material ATI 718Plus) was built with controlled porosity by varying laser power and scanning speed. This test caused various types of porosity, such as lack-of-fusion and keyhole formation, with varying degrees of severity in the part. The meltpool was continuously monitored using a dual-wavelength imaging pyrometer installed in the machine. Physically intuitive process signatures, such as meltpool length, temperature distribution, and ejecta (spatter) characteristics, were extracted from the meltpool images. Subsequently, relatively simple machine learning models, e.g., K-Nearest Neighbors, were trained to predict both the severity and type of porosity as a function of these physics-informed meltpool signatures. These models resulted in a prediction accuracy exceeding 95% (statistical F1-score). The same analysis was carried out with a complex, black-box deep learning convolutional neural network which directly used the meltpool images instead of physics-informed features. The convolutional neural network produced a comparable F1-score in the range of 89–97%. Finally, these results demonstrate that using pragmatic, physics-informed meltpool signatures within a simple machine learning model is as effective for flaw prediction in LPBF as using a complex and computationally demanding black-box deep learning model.

36 MATERIALS SCIENCE↗

Error field measurements with rotating RMP fields for DIII-D H-mode

3D magnetic sensors are employed to identify the amplitude and toroidal phase of error fields (EF) by analyzing the torque balance for magnetic islands entrained by rotating resonant magnetic perturbations (RMPs) in DIII-D H-mode plasmas. This technique of torque balance allows for efficient error field identification, offering a valuable tool for scenario-specific and optimized error field compensation (EFC) and requires only magnetic diagnostics. The torque balance used in this work includes the contribution from electromagnetic torque due to error fields, wall response, RMP fields, and viscous. Results show that viscous torque plays a crucial role, particularly during locked modes and H-mode plasmas, ensuring accurate data fits with lower residuals. The torque balance technique reveals that the L- and H-mode plasmas have distinct EF configurations, and consistent with a model-based EF analysis including MHD response in IPEC and the SURFMN EF simulation. This technique shows great robustness in measuring the intrinsic EF amplitude regardless of its amplitude or toroidal phase. Repeated discharges with EFC disparities exhibit consistent results of intrinsic error field within a reasonable range near the “standard” error field compensation. Additionally, the use of a rotating n = 1 resonant magnetic perturbation offers the advantage of reducing disruption risks by entraining saturated magnetic islands. These findings are instrumental for optimizing EF correction in fusion devices, thereby enhancing tearing mode suppression and overall plasma stability.

3D magnetic sensors↗