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At least 163 records · Page 9

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NASA NTRS1990

Fourier transform infrared (FTIR) fiber optic monitoring of composites during cure in an autoclave

Real-time in situ monitoring of the chemical states of epoxy resins was investigated during cure in an autoclave using infrared evanescent spectroscopy. Fiber evanescent sensors were developed which may be sandwiched between the plies of the prepreg sample. A short length of sapphire fiber was used as the sensor cell portion of the fiber probe. Heavy metal fluoride glass optical fiber cables were designed for connecting the FTIR spectrometer to the sensor fiber within the autoclave. The sapphire fibers have outstanding mechanical thermal properties which should permit their use as an embedded link in all thermoset composites. The system is capable of operation at a temperature of 250 C for periods up to 8 hours without major changes to the fiber transmission. A discussion of the selection of suitable sensor fibers, the construction of a fiber-optic interface, and the interpretation of in situ infrared spectra of the curing process is presented.

Druy, Mark A.↗

DOE OSTI2023

Distributed Coaxial Cable Sensors for In-Situ Condition Based Monitoring of Coal-Fired Boiler Tubes

The increasing contributions of renewable energy sources present new challenges to the operation and maintenance of the existing coal-fired power plants. One of the major operational risks is the unexpected failure of superheater boiler tubes, leading to the most unplanned power plant outrages. The boiler tube failure is difficult to predict due to the harsh operating environments. Therefore, condition-based monitoring (CBM) with a reliable high temperature sensor becomes necessary to produce a meaningful assessment of the health condition of boiler tubes and their remaining lifetime. In this work, the stainless-steel and quartz coaxial cable sensor (SSQ-CCS) is proposed for in-situ distributed monitoring of the boiler tube temperatures in existing coal-fired power plants. Comprehensive tests have been conducted with an in-house testing facility at Clemson University to study and evaluate the sensors’ performance in the temperature range of 100℃ to 600℃. The results indicated that the measurement resolution of the SSQ-CCS sensor is better than 1℃, and the drift is less than 2% over long-period testing. Meanwhile, multi-physics finite element analysis has been conducted to optimize the design and evaluate the safety of the SSQ-CCS temperature sensor under various operational conditions. Based on the performance obtained in the laboratory-scale testing, a field test has been implemented at a power plant. Four SSQ-CCS temperature sensors were installed for in-situ monitoring of the temperatures of a power plant’s superheat tube assembles. The data acquisition system has been successfully set up and collected sensing signals for more than three months. The sensing signals have been post-processed, and the monitored temperature history through the SSQ-CCS temperature sensor has been validated and compared with the conventional high temperature thermal couple data.

Jiao, Xinyu↗

DOE OSTI2022

In-process monitoring and prediction of droplet quality in droplet-on-demand liquid metal jetting additive manufacturing using machine learning

Abstract In droplet-on-demand liquid metal jetting (DoD-LMJ) additive manufacturing, complex physical interactions govern the droplet characteristics, such as size, velocity, and shape. These droplet characteristics, in turn, determine the functional quality of the printed parts. Hence, to ensure repeatable and reliable part quality it is necessary to monitor and control the droplet characteristics. Existing approaches for in-situ monitoring of droplet behavior in DoD-LMJ rely on high-speed imaging sensors. The resulting high volume of droplet images acquired is computationally demanding to analyze and hinders real-time control of the process. To overcome this challenge, the objective of this work is to use time series data acquired from an in-process millimeter-wave sensor for predicting the size, velocity, and shape characteristics of droplets in DoD-LMJ process. As opposed to high-speed imaging, this sensor produces data-efficient time series signatures that allows rapid, real-time process monitoring. We devise machine learning models that use the millimeter-wave sensor data to predict the droplet characteristics. Specifically, we developed multilayer perceptron-based non-linear autoregressive models to predict the size and velocity of droplets. Likewise, a supervised machine learning model was trained to classify the droplet shape using the frequency spectrum information contained in the millimeter-wave sensor signatures. High-speed imaging data served as ground truth for model training and validation. These models captured the droplet characteristics with a statistical fidelity exceeding 90%, and vastly outperformed conventional statistical modeling approaches. Thus, this work achieves a practically viable sensing approach for real-time quality monitoring of the DoD-LMJ process, in lieu of the existing data-intensive image-based techniques.

Gaikwad, Aniruddha (ORCID:0000000285642621)↗

DOE OSTI2023

Optimization of La 2–x Sr x CuO 4 Single Crystal Film Growth via Molecular Beam Epitaxy

Atomic layer-by-layer molecular beam epitaxy (ALL-MBE) combined with ozone is one of the best methods to fabricate single-crystal thin films of complex oxides. Cuprate such as La 2-x Sr x CuO 4 (LSCO) is a representative complex-oxide high-temperature superconductor (HTS) material. Our group utilizes this method to produce high-quality single-crystal HTS films with atomically smooth surfaces and interfaces. In addition, ALL-MBE enables us to engineer multilayer heterostructures with atomic precision. This allows the fabrication of tunnel junctions, various nanostructures, and other HTS devices of interest for superconducting electronics. We have synthesized over three thousand LSCO thin films in the past two decades. These films’ structural and electronic properties have been studied and characterized by various methods. Here, we distill the extensive experience we accumulated into a step-by-step protocol to fabricate atomically perfect LSCO films. The recipe includes substrate preparation, ozone generation and distillation, source calibration, the in situ monitoring of the film synthesis, post-growth annealing, and ex situ characterization. It discloses a reproducible way to fabricate single-crystal LSCO films for basic research and HTS electronic applications.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

NASA NTRS2021

Illinois Disasters: Utilizing NASA Earth Observations to Enhance Drought Monitoring in Illinois

Drought and flooding in Illinois have severe impacts on the communities and ecosystems of the state. Soil moisture is a valuable indicator of drought and flood vulnerability but can be difficult to measure since in situ monitoring is limited to discrete stations throughout the state. The team created a framework to compare in situ, modeled, and NASA satellite soil moisture measurements to increase the spatial coverage of soil moisture monitoring. The team partnered with the Illinois State Weather Survey, USDA Midwest Climate Hub, NOAA Regional Climate Services of the Central Region, NOAA National Integrated Drought Information System’s Midwest Drought Early Warning System, and the NOAA North Central River ForecastCenter. The team standardized and compared soil moisture data from NASA’s Soil Moisture Active Passive (SMAP) mission, modeled soil moisture outputs from NASA’s SPoRT Land Information System (SPoRT-LIS), and in situ measurements from the Illinois State Weather Survey’s Water and Atmospheric Resources Monitoring (WARM) program. Compared to the WARM data, the satellite and modeled data showed seasonally variable differences and bias. The difference was highest in the winter months and lowest in the late summer and early fall months for the SMAP and SPoRT-LIS data products. SPoRT-LIS produced lower seasonal variability and SMAP demonstrated higher correlation values and lower differences. These analyses suggest that both SMAP and SPoRT-LIS products offer unique strengths and limitations when used for soil moisture monitoring

Joshua Green↗

DOE OSTI2025

Defect Detection Model Development for Large Scale Thermoplastic Printing

Large-format additive manufacturing (LFAM) offers several advantages, including high throughput, cost-effective pellet-fed extrusion, and the capability to produce large-scale structures. The main pain points of LFAM include start and stops during the printing process, warpage, long layer times that lead to bead freezing, and bead separation due to shrinkage. These issues can lead to overfill, underfill and buildup of material in different sections of a print. This can lead to hidden defects embedded within the printed layers, or even ultimate failure of the printed structure. This ensures these defects can only be identified through nondestructive testing (NDT) inspection methods after printing, which can be timely and costly. Aligned Vision work specializes in 2D projectors with visual inspection systems and machine learning. Traditionally system is used for composite layup and layup inspections. In this work we used the LFAM system at Oak Ridge National Laboratory to create defect rich samples. The Aligned Vision inspection system then performed in-situ monitoring of the print process after each part was printed. This in-situ vision inspection system was used to develop a layer-by-layer inspection model that looks for overfill, underfill, and the buildup of defects using only a camera-based vision system. This leads to the assurance of high-quality production components.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Online thermal profile prediction for large format additive manufacturing: A hybrid CNN-LSTM based approach

Large format additive manufacturing (LFAM) is an advanced 3D printing technique that efficiently fabricates large-scale components through a layer-by-layer extrusion and deposition process. Accurate surface layer temperature monitoring is essential to prevent manufacturing failures and ensure final product quality. Traditional physics-based offline approaches for simulating thermal behavior are often inefficient and complex, posing challenges on real-time, in-situ monitoring. Here, to address this, we propose a data-driven hybrid CNN-LSTM model to predict sequential thermal images of arbitrary length using real-time infrared thermal imaging. In this approach, a Convolutional Neural Networks (CNN) is trained offline to capture spatial features, reduce dimensional complexity, and enhance time efficiency, while a stacked Long Short-Term Memory (LSTM) is applied online to capture temporal information for improved prediction of future thermal behavior in subsequent printing layers. Model performance is evaluated using MSE, SSIM, and PSNR metrics and is benchmarked against stacked LSTM and convolutional LSTM models, demonstrating superior accuracy and applicability. Additionally, to mitigate noise from moving extruders and gantry backgrounds in thermal images, a fine-tuned semantic segmentation model is implemented offline to extract printing geometry, enabling precise temperature tracking along the tool path for further thermal analysis. The frameworks developed in this study significantly advance temperature monitoring, thermal analysis, and in-situ manufacturing control for LFAM, bridging the gap between theoretical modeling and practical application.

Geometry extraction↗

DOE OSTI2022

A systematic study and framework of fringe projection profilometry with improved measurement performance for in-situ LPBF process monitoring

Fringe Projection Profilometry (FPP) is a cost-effective and non-invasive technology that has been shown to measure finer features. Here, in this work, we developed an in-situ FPP method to measure the dynamic topography of powder bed and printed layer during Laser Powder Bed Fusion (LPBF) additive manufacturing (AM) process. A systematic study towards developing a comprehensive framework of LPBF-specific FPP is demonstrated to enhance and evaluate the performance of applying FPP for in-situ LPBF monitoring, including 1) a modified sensor model with localized correction; 2) improved phase unwrapping with FFT filtering 3) quantitative uncertainty analysis; and 4) experimental validation with ex-situ characterization. The developed LPBF-specific FPP system and methods are implemented on a commercial LPBF-AM machine, achieving better accuracy, more robustness, and increased field of view while maintaining sufficient measurement range and decent resolution, in contrast to literature methods. The established FPP framework will facilitate the development of closed-loop control strategies for advancing LPBF based AM.

42 ENGINEERING↗

NASA NTRS2013

Monitoring Temperature in High Enthalpy Arc-heated Plasma Flows using Tunable Diode Laser Absorption Spectroscopy

A tunable diode laser sensor was designed for in situ monitoring of temperature in the arc heater of the NASA Ames IHF arcjet facility (60 MW). An external cavity diode laser was used to generate light at 777.2 nm and laser absorption used to monitor the population of electronically excited oxygen atoms in an air plasma flow. Under the assumption of thermochemical equilibrium, time-resolved temperature measurements were obtained on four lines-of-sight, which enabled evaluation of the temperature uniformity in the plasma column for different arcjet operating conditions.

Martin, Marcel Nations↗

DOE OSTI2024

Height-resolved emission spectroscopy and high-speed imaging of the TiAl6V4 vapor plume under laser powder bed fusion conditions

Optical emission spectroscopy is increasingly used as an in situ monitoring technique during laser powder bed fusion (LPBF) because plume emission holds elemental information not found in other in situ sensing techniques. This work explores the shape, stability, and temperature of the emission plume above the melt pool of Ti6Al4 V undergoing laser scans under LPBF-like processing conditions, using high-speed video and height-resolved spectroscopy to study the details of plume dynamics. Optical emission spectroscopy is conducted in the 480 nm to 525 nm region, where Ti emission is strong, with 0.3 mm vertical resolution above the baseplate. The Boltzmann plot method is used to determine temperature at each probed elevation, which indicates that the hottest location of the plume is occasionally elevated 0.3 mm to 0.6 mm above the scanning surface. The results show that the plume shape, stability, temperature, and spectra are highly dependent on the processing conditions. We highlight some of the complexities of optical emission spectroscopy and discuss potential challenges for implementing optical emission spectroscopy across an entire build.

36 MATERIALS SCIENCE↗

NASA NTRS1992

Improved instrumentation for monitoring the diurnal and seasonal cycles in the dielectric properties of forest canopies

The design and implementation of a dielectric measurement system that facilitates the automated and continuous in situ monitoring of the dielectric properties of several canopy constituents is presented. This system utilizes the same coaxial line reflection coefficient measurement technique as the portable dielectric probe (PDP) while incorporating several features that facilitate the automated monitoring of canopy dielectric properties. The new system is capable of continuously monitoring the dielectric properties of the canopy constituents in a near-simultaneous fashion. The implementation of a data logger as a user interface has increased the number of measurements that the instrument is able to store in memory while significantly improving system reliability.

Guerra, Abel G.↗

DOE OSTI2020

In situ laser reflectivity to monitor and control the nucleation and growth of atomically thin 2D materials*

The growth of atomically thin two-dimensional (2D) layered and other quantum materials is typically performed without in situ monitoring or control. Here, a simple laser reflectivity approach is demonstrated to provide in situ control over sub-monolayer thickness and growth kinetics during pulsed laser deposition (PLD) of MoSe 2 layers. First, the general technique is presented with emphasis on designing the maximum sensitivity of the optical contrast through consideration of Fresnel's equations with proper choice of layer thickness, substrate, and laser monitoring wavelength, incidence angle, and laser polarization. Then the 632.8 nm optical reflectivity of MoSe 2 layers on SiO 2 /Si substrates was predicted and compared with in situ monitoring of MoSe 2 growth by PLD under actual growth conditions using a probe HeNe laser beam. The measurements showed high sensitivity and excellent agreement with MoSe 2 surface coverages calculated from atomic resolution STEM analysis of 2D layers deposited in arrested growth experiments. Finally, growth kinetics revealed by these measurements showed sigmoidal nucleation and growth stages in the formation of the 2D MoSe 2 layers that are described by a simple model, indicating the promise of the laser reflectivity technique for in situ monitoring and control of 2D materials deposition.

2D materials↗

DOE OSTI2025

Laser-Induced Breakdown Spectroscopy (LIBS) Sensing for Environmental and Subsurface Monitoring

Groundwater monitoring is essential to timely and accurately reflect the current situations and the trends of water quality. However, the long-term stability and survival of any potential in-situ monitoring method is threatened by the harsh conditions and the groundwater monitoring in downhole environments poses numerous challenges to the sensor community. Laser induced breakdown spectroscopy (LIBS) has been demonstrated as a promising technology for chemical monitoring in high-temperature high-pressure (HTHP) environments and hard to reach places. The technique demonstrates several advantages, such as rapid, real-time, in-situ, and simultaneous detection of multiple elements with simple or no sample preparation. This chapter includes a brief review of the field-portable LIBS systems, and development of a compact, robust, and simple LIBS instrument for downhole HTHP water quality monitoring. The fieldable prototype sensor is tested in an onsite monitoring well where trace elements’ concentrations are tracked over an extended period. The testing has verified that the fiber coupled design performs as desired. The system shows good calibration linearity for tested elements and collection times, and Limits of Detection (LODs) that are comparable to those of tabletop LIBS instruments. In addition to groundwater quality monitoring, the fabricated LIBS-based sensor could have widespread sub-surface detection applications.

Jain, Jinesh [NETL Site Support Contractor, Nation↗

DOE OSTI2021

Visualizing time-dependent microstructural and chemical evolution during molten salt corrosion of Ni-20Cr model alloy using correlative quasi in situ TEM and in situ synchrotron X-ray nano-tomography

In situ monitoring of corrosion processes is important to fundamentally understand the kinetics and evolution of materials in harsh environments. A quasi in situ transmission electron microscopy technique was utilized to study microstructural and chemical evolution of a Ni-20Cr disc sample 6 exposed to molten KCl-MgCl 2 salt for 60 s in consecutive 20 s iterations. In situ synchrotron X-ray nano-tomography was performed to characterize the morphological evolution of a Ni-20Cr microwire exposed to molten KCl-MgCl 2 . Here, both techniques captured key corrosion events and revealed mechanisms at different time and length scales, potentially bringing greater insights and 10 deeper understanding beyond conventional analysis.

36 MATERIALS SCIENCE↗

NASA NTRS1997

Application of Laser Based Ultrasound for NDE of Damage in Thick Stitched Composites

As design engineers implement new composite systems such as thick, load bearing composite structures, they must have certifiable confidence in structure s durability and worthiness. This confidence builds from understanding the structural response and failure characteristics of simple components loaded in testing machines to tests on full scale sections. Nondestructive evaluation is an important element which can provide quantitative information on the damage initiation, propagation, and final failure modes for the composite structural components. Although ultrasound is generally accepted as a test method, the use of conventional ultrasound for in-situ monitoring of damage during tests of large structures is not practical. The use of lasers to both generate and detect ultrasound extends the application of ultrasound to in- situ sensing of damage in a deformed structure remotely and in a non-contact manner. The goal of the present research is to utilize this technology to monitor damage progression during testing. The present paper describes the application of laser based ultrasound to quantify damage in thick stitched composite structural elements to demonstrate the method. This method involves using a Q-switched laser to generate a rapid, local linear thermal strain on the surface of the structure. This local strain causes the generation of ultrasonic waves into the material. A second laser used with a Fabry-Perot interferometer detects the surface deflections. The use of fiber optics provides for eye safety and a convenient method of delivering the laser over long distances to the specimens. The material for these structural elements is composed of several stacks of composite material assembled together by stitching through the laminate thickness that ranging from 0.5 to 0.8 inches. The specimens used for these nondestructive evaluation studies had either impact damage or skin/stiffener interlaminar failure. Although little or no visible surface damage existed, internal damage was detected by laser based ultrasound.

Anastasi, Robert F.↗

NASA NTRS2026

The Operational NASA Anomaly Gas Analyzer and Exploration Follow-Ons

The NASA Anomaly Gas Analyzer (AGA) is the culmination of nearly ten years of advancement of core technology originally developed by Vista Photonics through the Small Business Innovation Research (SBIR) program and expanded using NASA program funding. The AGA is a portable, battery operated, optical gas detection instrument for continuous monitoring of H 2 O, CO 2 , O 2 , CO, NH 3 , HCN, HF, HCl in the spacecraft environment. Real time, in-situ monitored, gas concentrations are communicated at 1 Hz through a built-in display on-orbit and additionally through a serial interface on the ground. The instruments function over the typical range of temperatures and pressures required for the spacecraft environment. A ten-year operational life is targeted. Seven AGA instruments are currently deployed on the International Space Station and two Orion-specific units are manifested for Artemis 2. A variation of the operational AGA is under development for lunar Human Landing Systems. A wider calibrated operating pressure envelope is required in this application. Otherwise, the instruments straightforwardly address lessons learned from the original AGA by improving aspects of thermal control, ruggedness, and ease-of-use. A subset of AGA-developed sensed gases (H 2 O, CO 2 , O 2 ) is the subject of the Primary Constituent Monitor (PCM) development for the Habitation and Logistics Outpost (HALO) destined for lunar orbit. Two PCMs will be installed in HALO as part of the environmental control loop where they will interface with vehicle power and communications. While the basic sensor techniques are unchanged from the AGA, these instruments have been radiation hardened to survive for many years in the harsh target environment. Current development status for these instruments will be presented along with recent developments of a naval submarine variant.

Air Monitoring↗

NASA NTRS2026

The Operational NASA Anomaly Gas Analyzer and Exploration Follow-Ons

ECLSS↗

DOE OSTI2021

Developing a strategy for the national coordinated soil moisture monitoring network

Soil moisture is a critical land surface variable, affecting a wide variety of climatological, agricultural, and hydrological processes. Determining the current soil moisture status is possible via a variety of methods, including in situ monitoring, remote sensing, and numerical modeling. Although all of these approaches are rapidly evolving, there is no cohesive strategy or framework to integrate these diverse information sources to develop and disseminate coordinated national soil moisture products that will improve our ability to understand climate variability. The National Coordinated Soil Moisture Monitoring Network initiative has developed a national strategy for network coordination with NOAA's National Integrated Drought Information System. The strategy is currently in review within NOAA, and work is underway to implement the initial milestones of the strategy. This update reviews the goals and steps being taken to establish this national-scale coordination for soil moisture monitoring in the United States.

54 ENVIRONMENTAL SCIENCES↗