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DOE OSTI2018

An Historic Perspective of NPDES Individual Permit for Storm Water Discharges from Solid Waste Management Units at Los Alamos National Laboratory - 18667

The Los Alamos National Laboratory (LANL) and the associated communities of Los Alamos and White Rock are located in Los Alamos County in north-central New Mexico approximately 60 mi north-northeast of Albuquerque and 25 mi northwest of Santa Fe. The 36-mi{sup 2} facility is situated on the Pajarito Plateau, which consists of a series of fingerlike mesas separated by deep east-to-west oriented canyons cut by predominately ephemeral and intermittent streams. The mesa tops range in elevation from approximately 7800 ft. on the flanks of the Jemez Mountains to about 6200 ft. at their eastern termination above the Rio Grande Canyon. The land surrounding the Laboratory is largely undeveloped. Public access to much of the facility is limited for safety and security reasons. Large tracts of surrounding land are held by the U.S. Forest Service (Santa Fe National Forest), the Bureau of Land Management (Bandelier National Monument), the General Services Administration and San Ildefonso Pueblo. Storm water discharges from Solid Waste Management Units (SWMUs) have been regulated at the LANL since the early 1990's and have evolved into an Individual Stormwater Permit (IP) that may be one of the most complex in the nation. Historically, storm water discharges from SWMUs at LANL were regulated under a nationwide general permit using a watershed based approach requiring a Storm Water Pollution Prevention Plan (SWPPP), monitoring at sub-watershed scale 'USGS like' gage stations, and inspection and maintenance of erosion controls. In 2001, the Cerro Grande Fire destroyed many Laboratory structures, residential homes and over 80,000 acres of forested lands in the upper watershed above Los Alamos that significantly changed the local hydrology. Several years later, a Federal Facilities Compliance Agreement (FFCA) was issued by U.S. Environmental Protection Agency (USEPA) that was followed by a Clean Water Act lawsuit filed by concerned citizens, the result of which required more focus on stormwater discharges from individual SWMUs and an IP covering over 400 Sites. The IP contains non-numeric technology-based effluent limitations, coupled with a comprehensive, coordinated inspection and monitoring program, to minimize pollutants in LANL's storm water discharges associated with historical industrial activities from specified Sites. Non-numeric technology-based effluent limitations include minimizing pollutants in discharges through erosion and sedimentation controls, management of run-on and runoff, employee training, inspection and maintenance of controls, annual reporting and public involvement. The IP establishes Target Action Levels (TALs) that are equivalent to New Mexico State water-quality criteria. These TALs are used as benchmarks to determine the effectiveness of control measures implemented under the IP. That is, storm water quality sample results from SWMU discharges are compared with applicable TALs. If one or more sample results exceed a TAL, LANL must take additional corrective action. The TAL results are also confounded by high levels of naturally occurring constituents such as aluminum and gross alpha, and urban constituents such as copper, zinc and PCBs which may not be a source from the regulated SWMU. Due to the remote rugged terrain, security access issues, number of monitoring locations, stringent TALs, reporting requirements and public involvement requirements, this permit is likely one of the most stringent and complex in the country. The Laboratory has implemented this permit in a compliant manner for the past seven years and is anticipating the issuance of a new permit in the next few months. This paper will cover permit requirements related to control measure installations, monitoring, reporting and public involvement as well as process improvements and remaining water quality initiatives such as developing studies to address issues such as discriminating between natural background levels and LANL-related contaminants during the execution of this unique permit. (author)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2019

Handling and Treatment of Sodium-Potassium Alloy (NaK) after the Loss of Key Personnel - 19002

In September 2010, during cleanup and removal efforts associated with a glovebox containing a sodium-potassium alloy (NaK) cooling system, a NaK reaction event occurred. Near the end of the evolution, which was at a Materials and Fuels Complex (MFC) research facility at the Idaho National Laboratory, a 2 to 3-ounce sample of NaK was being transferred from a metal can to a polyethylene bottle so it could be sent to the disposal outlet for verification analysis. During the transfer, a reaction of the NaK with ambient air was observed in both the metal can and sample container. The potential for a reaction was identified during the planning of this activity and mitigating steps were included in the procedures. In response, the two containers were flooded with argon, closed, and observed overnight. No additional reaction was noted. The sample container and metal can were packaged into a 10-gallon drum and transferred to a permitted storage location pending disposal. While the other containers generated from the deactivation and decommissioning activity were sent off-site for disposal, the 10-gal drum remained due to concerns by a staff specialist that the material could contain potassium superoxide (KO{sub 2}) as a result of the reaction event. The intent at that time was to treat the NaK in a Resource Conservation and Recovery Act (RCRA)-permitted treatment facility at MFC, instead of sending it off-site for disposal. The container was labeled, inspected, and managed as a hazardous waste. Due to the complexities associated with safely handling and treating NaK and KO{sub 2}, the container remained in storage. Treatment and disposal of the NaK and KO{sub 2} container was revisited in 2016, when researchers and chemists were consulted regarding the potential for superoxide formation and the best means to safely store and treat the container. The facility came to realize that due to the retirements of key personnel, it needed to provide current employees operational experience with the handling and treatment of NaK. An outside company was identified and contracted to provide training and consulting services. Several Battelle Energy Alliance, Inc. (BEA) personnel then attended an alkali metals safety training class. The training course provided participants with classroom and hands-on instruction associated with: - Hazards associated with handling and using sodium and NaK; - Proper personal protection equipment, spill control techniques, and first aid; - Common design approaches for buildings, systems, and equipment used to contain sodium and NaK; - What to expect in the event of a water reaction and how to respond; - How to properly prepare for a fire and contain/extinguish small metal fires; - A hands-on demonstration of NaK reaction and controls. Following the training, a procedure was developed to open the container, and inspect and treat the NaK. In June 2017, facility operations personnel successfully completed the inspection and treatment of the NaK drum, eliminating the legacy liability. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2019

The CNSC's Inspector Training and Qualification Program and its Importance to the Nuclear Industry - 19370

Trained, qualified, and designated staff at the Canadian Nuclear Safety Commission (CNSC) conduct inspections of licensed nuclear sites as a method of compliance verification. This paper will describe the unique and comprehensive qualification process for CNSC inspectors, known as the Inspector Training and Qualification Program (ITQP). The ITQP includes service-line-specific training that is unique to each inspection group within the CNSC, dependent on the facility/industry type. The training requirements specific to staff in the Wastes and Decommissioning Division and its impact on safety at waste management sites across Canada will be discussed. This paper will specifically identify the importance of CNSC inspector training and detail how the unique training program requirements enable the CNSC to better identify and encourage compliance among nuclear waste and decommissioning sites in Canada. CNSC inspectors are designated under section 29 of the Nuclear Safety and Control Act (NSCA), and the powers of inspectors are outlined in section 32 of the NSCA. Having trained, qualified, and designated inspectors is paramount for both the CNSC and the nuclear industry. For the CNSC, this ensures that staff in the field are aware of potential hazards and how to mitigate such hazards (if applicable), that staff understand the regulatory framework and how to measure compliance against it, and that staff consistently apply CNSC values across the nuclear industry. For the industry, this ensures that staff present at nuclear facilities are knowledgeable and professional, that inspections are conducted in a consistent manner, and that any compliance actions issued are measurable and defendable against the regulatory framework. The CNSC's ITQP incorporates both theoretical (in-class and online) and practical training, and is broken down into six categories: mandatory training for all new employees; core training; service-line-specific training; on-the-job training; CNSC regulations training; and, recommended additional training. This paper will discuss in detail the specific aspects of each of these categories, the importance of each category including the difference between knowledge and skills acquired in theoretical versus hands-on training, and how CNSC staff in designated inspector positions (inspectors-in-training) progress through the program. The complete list of core training and service-line-specific training for inspectors in the Wastes and Decommissioning Division, including re-qualification requirements, will be explored throughout the paper. It is further important that CNSC designated inspectors undergo continuous learning to ensure that their skills remain up to date, as well as to ensure that inspectors requalify at defined intervals to enable the maintenance of the core knowledge and skills with which the determination of the person's qualification was based. The steps involved in this requalification process, as well as the importance of continuous learning and the maintenance of skills and knowledge will be further discussed. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2020

WIPP Safety Significant Confinement Ventilation System (SSCVS) Quality Assurance Program - 20237

Construction and major equipment fabrication are underway for a new ventilation exhaust system at the Waste Isolation Pilot Plant (WIPP). The new system will provide continuous HEPA filtration of the exhaust from the WIPP underground while meeting the ventilation demands for expanded waste emplacement and mining operations over the next 40 years. The SSCVS project has proceeded with the awarding of CD-3A for Long Lead Procurements followed by CD-2/3 approval for the construction of the facilities. The SSCVS project team made the decision to increase the quality oversight throughout the complete project per the Project Quality Assurance Plan (PQAP) such that it can ensure the final products meet applicable NQA-1 requirements and general quality requirements, and that the project will proceed to operations without significant delays due to post installation quality concerns. The PQAP was established prior to approval of the project at the CD-2/3 milestone. The SSCVS project has 2 major long lead procurements which commenced with the awarding of CD-3A. These procurements include the HEPA filter housing assemblies and the Exhaust Fans. There are 22 HEPA filter assemblies for the SSCVS, which are designated Safety Significant for pressure boundary confinement, per the approved PDSA. The exhaust fans also have Safety Significant components to maintain the pressure confinement boundary. NWP made the decision to install resident Quality Inspectors at the fabrication facilities to ensure the documentation for each fabricated unit meets all the QA requirements as defined in the respective contract documents. For the construction of the SSCVS Salt Reduction Building (SRB) and New Filter Building (NFB), dedicated, on-site quality inspectors have been utilized to ensure that all work being performed will comply with quality requirements and the Special Inspections as defined in IBC-2015. At each stage of inspection, hold points are placed into the work packages to ensure NWP QA personnel are present to inspect and verify the installations are in accordance with the design specifications, codes and standards. With this level of oversight, NWP anticipates that the level of quality related issues, as seen on multiple other DOE complex site projects, will be avoided and that the commissioning, start-up and hot operations will progress in a timely fashion, as all documentation will be in place and approved prior to initiation of these activities. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2020

Aging of Concrete for the Evaluation of Repair Materials to Protect the Walls of the HCAEX Tunnel at Savannah River - 20301

H-Canyon, located in the Savannah River site, is a unique facility for chemical reprocessing of plutonium, highly-enriched uranium, and other radioactive materials. The exhaust gases of the H-Canyon are sent through the H-Canyon Exhaust (HCAEX) tunnel for contamination removal. Robotic inspections of the tunnel revealed significant degradation of the reinforced concrete structure that was associated with acid attack, and could compromise the structural stability of the tunnel. Thus, the identification and evaluation of potential repair materials that could be applied on the degraded walls to mitigate and prevent further degradation is of significant interest to the Department of Energy and the Savannah River representatives. This research effort has been divided into two phases: 1) Development and evaluation of aged concrete under accelerated aging conditions (which is the focus of this paper) and 2) Evaluation of potential repair materials applied on aged and non-aged concrete under simulated aggressive conditions. In order to develop and evaluate concrete samples exposed to accelerated aging conditions in simulated aggressive environments, a literature review of the HCAEX tunnel was conducted that included 1) characterization and extent of the concrete damage, 2) environmental conditions inside the tunnel and 3) primary deterioration mechanisms. In addition, potential coatings and/or repair materials for degraded concrete surfaces exposed to aggressive environments (primarily acidic) were selected from the literature review and the most common testing and measurements for evaluating acid attack phenomena, erosion, etc. were reviewed. From the literature review findings, a preliminary bench-scale test plan for the concrete aging was developed, including accelerated aging tests with aggressive conditions (acid fumes, humidity, etc.). Concrete samples were exposed to the aging accelerated conditions (e.g. immersion in acid solutions) and visual inspection, mass loss and pH change (acid solution) were recorded over time. Correlations between the visual inspection, mass loss and pH changes results and the aging time or the aging conditions were developed. Specimens submitted to the highest acid concentration showed the fastest and most intense degradation. The type of coarse aggregate (limestone) used for the concrete seemed to be the cause of the fastest aging observed, compared to the cement paste. The research findings created the foundation for the ongoing investigation, in which new concrete samples with a mix design similar to the HCAEX tunnel will be tested and will serve as the substrate for testing the selected coatings and /or repair materials. In this paper, the literature review and preliminary results from the aging tests are provided. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2016

Estimating the Penetration Depth and Orientation of Stress Corrosion Cracks Using Time-Reversal Acoustics

Austenitic stainless steels are known to be susceptible to stress corrosion cracking (SCC), which is an aggressive type of corrosion that exists when a material under tensile stress is placed in a corrosive environment. This is of particular concern as the processing (i.e., cold rolling) and construction (welding) of storage canisters produce an inherent residual stress in metals that can lead to SCC. In this context, our objective is to study the formation of stress corrosion cracks within Type 304L stainless steel, which is frequently used in containers for used nuclear fuel disposal. The conditions present in storage canisters (i.e., elevated temperatures, high residual stresses near welds, and exposure to humidity and chloride) make them susceptible to SCC, potentially leading to critical through-wall failure, and thus loss of containment. The timescales on which through-wall failure is expected in a storage canister under typical conditions is on the order of tens of years. While through-wall flaws are catastrophic (e.g., release of helium and fission gases), the long timescales allow for routine inspection, and potentially mitigation, providing methods exist. This paper is focused on the former problem, i.e. detection of SCC, and the development of a tool for inspection of storage canisters. We will discuss the recent work we did on detecting the presence of SCC as well as imaging on its orientation and penetration depth using an acoustic technique developed at Los Alamos National Laboratory (LANL). This technique has been applied successfully in the laboratory on stainless steel samples with SCC provided by General Electric (GE) and the Electric Power Research Institute (EPRI). Recently, we have also demonstrated that this technique can be deployed for field inspections in tight and confined spaces. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2017

Neutron Irradiation of Nuclear Structural Materials Fabricated by Powder Metallurgy with Hot Isostatic Pressing

An irradiation campaign intended to produce data necessary to qualify various reactor structural materials fabricated by powder metallurgy with hot isostatic pressing (PM/HIP) is currently in progress. Manufacturing processes have considerable influence over the safety and integrity of nuclear reactor vessels and internal components. Established processes such as casting, plate rolling and welding, forging, drawing, and extrusion have been used to fabricate structural and pressure-retaining materials used in the nuclear power industry for the past 60 years. However, weldability and inspectability are ongoing issues in the manufacture of reactor vessels and internals. Furthermore, these components are subject to harsh service environments, which combine high radiation fluence, high temperature, and mechanical stress. These conditions can accelerate material degradation and failure, with the most extreme degradation often occurring at weldments and in poorly manufactured or inspected components. Advanced reactor designs and lifetime extensions to the existing fleet of light-water reactors (LWRs) will exacerbate materials degradation issues by increasing the duty on reactor internals. Thus, developing reliable manufacturing processes wherein high-quality weldments and inspections can be performed is of great importance to the continued safety and operation of nuclear power plants.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2021

Active Neutron Interrogation as a Method for Verification of the Absence of Special Nuclear Material in Arms Control Dismantlement

The next step in arms control reductions will deal with both strategic and non-strategic weapons, presenting new and hard challenges for verification. One verification approach that might be used in support of these reductions is the concept of deferred verification, which forgoes inspections at sensitive nuclear sites and relies on an inspection regime having access to the open segment of a State's nuclear sector, in "monitored transfer zones." A component of this approach is the anticipated need for an instrument suite capable of detecting well-shielded highly-enriched uranium or plutonium where it isn't supposed to be. This specific need was recently identified by the United Nations Institute for Disarmament Research in an enabling operating concept they call "contain and dispose." At the foundation of this approach is the idea that items declared as "not nuclear" are, by definition, not treaty limited and are thus "fair-game" for inspection and questioning. Active Neutron Interrogation (ANI), using beta-delayed neutron emissions as the signature for special nuclear material (SNM) detection, is a promising method to address this challenge. The method is quick, has high sensitivity and high specificity for detecting shielded SNM, is robust against changing background radiation environments, is robust against the presence of unknown shielding, and avoids the use of gamma-ray spectrometry which may introduce complications due to the potential release of sensitive information. This paper will present recent research activities exploring technical aspects of using ANI as a FAIRGAME verification method and discuss future prospects and research needs

46 - INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AN↗

DOE OSTI2026

WM26 Paper Multi-Robot Collaboration for Hazardous Environments

Hazardous nuclear and industrial facilities are rarely designed for robots. Work in these domains demand precise manipulation and robust mobility in cluttered, constrained spaces where off-the-shelf platforms struggle and “one-size-fits-all” machines become costly and complex. Idaho National Laboratory (INL) is developing an autonomous, multi-robot inspection system that coordinates task-specific platforms rather than relying on a single omni-tool robot. An electric truck serves as a power and compute hub for a custom manipulator co-developed with Florida International University (FIU), a commercial mini crawler, a pan–tilt–zoom camera, and a Nexxis Argus LiDAR mapping system. Working in concert, these robots generate spatial, radiation, and temperature maps of the pit environments at the Hanford Waste Tank Farms. These systems will capture visual records and environmental telemetry to allow for analysis post inspection. The system architecture uses Robot Operating System 2 (ROS 2) for publish/subscribe integration, NVIDIA Isaac Sim and Unity for simulation and visualization, and algorithms such as NVBlox to fuse data into unified 3D overlays. This robot-agnostic approach reduces operator burden by enabling autonomy across heterogeneous platforms and lets each robot be used where it is strongest. Having autonomous functions means operators don’t have to fully control multiple different components. The ease of use could allow for more widespread adoption of advanced robotics at waste management sites that see continued use. By coordinating simpler, purpose-built mechanisms, the approach lowers design and manufacturing complexity, reduces capital risk in contaminated settings, and improves controllability for complex inspection and manipulation tasks. We present the architecture, early results, and lessons learned from building and deploying this coordinated multi-robot system, with the goal of accelerating safe, cost-effective adoption of advanced robotics at waste-management sites.

42 - ENGINEERING↗

DOE OSTI2017

Frequency Domain Reflectometry NDE for Aging Cables in Nuclear Power Plants

Cable insulation polymers are among the more susceptible materials to age-related degradation within a nuclear power plant. This is recognized by both regulators and utilities, so all plants have developed cable aging management programs to detect damage before critical component failure in compliance with regulatory guidelines. Although a wide range of tools are available to evaluate cables and cable systems, cable aging management programs vary in how condition monitoring and nondestructive examinations are conducted as utilities search for the most reliable and cost-effective ways to assess cable system condition. Frequency domain reflectometry (FDR) is emerging as one valuable tool to locate and assess damaged portions of a cable system with minimal cost and only requires access in most cases to one of the cable terminal ends. Since laboratory studies to evaluate the use of FDR for inspection of aged cables can be expensive and data interpretation may be confounded by multiple factors which influence results, a model-based approach is desired to parametrically investigate the effect of insulation material damage in a controlled manner. This work describes development of a physics-based FDR model which uses finite element simulations of cable segments in conjunction with cascaded circuit element simulations to efficiently study a cable system. One or more segments of the cable system model have altered physical or electrical properties which represent the degree of damage and the location of the damage in the system. This circuit model is then subjected to a simulated FDR examination. The modeling approach is verified using several experimental cases and by comparing it to a commercial simulator suitable for simulation of some cable configurations. The model is used to examine a broad range of parameters including defect length, defect profile, degree of degradation, number and location of defects, FDR bandwidth, and addition of impedance-matched extensions to minimize the end-shadow effect.

Cable Inspection, Frequency Domain Reflectometry↗

DOE OSTI2012

Wind Turbine Manufacturing Process Monitoring

To develop a practical inline inspection that could be used in combination with automated composite material placement equipment to economically manufacture high performance and reliable carbon composite wind turbine blade spar caps. The approach technical feasibility and cost benefit will be assessed to provide a solid basis for further development and implementation in the wind turbine industry. The program is focused on the following technology development: (1) Develop in-line monitoring methods, using optical metrology and ultrasound inspection, and perform a demonstration in the lab. This includes development of the approach and performing appropriate demonstration in the lab; (2) Develop methods to predict composite strength reduction due to defects; and (3) Develop process models to predict defects from leading indicators found in the uncured composites.

17 WIND ENERGY↗

DOE OSTI2019

Determining moisture content of Traditional Chinese Medicines using a near-infrared LED-based moisture content sensor with spectrum analysis

In Traditional Chinese Medicine (TCM), moisture content (MC) inspection using voltage level or a lock-in amplifier, with a features-based near-infrared light-emitting diode sensor is possible. Abundant absorption response in a wide frequency range and information in both the time-domain and frequency-domain can be obtained, with the square excitation method. However, planeness, heterogeneous particle sizes, and measurement noise negatively affect the time-domain feature during MC inspection. In this work, spectrum analysis (SA) for feature extraction is investigated, to precisely measure the MC of Dutong pills. The principal components for low and high frequencies, are aimed at counteracting the dimensional methods, which are used for supplying the lower dimensional features. The SA experimental results demonstrate that the low frequency components, ranging from the base to the 3rd harmonic components, have a high linear correlation with the MC. The calibration and validation experimental results reveal that the MC can be a monotonic function about the SA amplitudes or first principal component (PC1), with the proposed sensor. This method has the potential to be used for gauging automatic, in situ MCs, particularly for quality control and Process Analytical Technology in TCM. Future research opportunities include improving accuracy and application of the method under field conditions.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2023

A semiempirical transparency model for dual energy cargo radiography applications

Cargo containers passing through ports are scanned by non-intrusive inspection systems to search for concealed illicit materials. By using two photon beams with different energy spectra, dual energy inspection systems are sensitive to both the area density and the atomic number of cargo contents. Most literature on the subject assumes a simple exponential attenuation model for photon intensity in which only free streaming photons are detected. However, this approximation neglects second order effects such as scattering, leading to a biased model and thus incorrect material predictions. This work studies the accuracy of the free streaming model by comparing it to simulation outputs, finding that the model shows poor atomic number reconstruction accuracy at high- Z and suffers significantly if the source energy spectra and detector response function are not known exactly. To address these challenges, this work introduces a semiempirical transparency model which modifies the free streaming model by rescaling different components of the mass attenuation coefficient, allowing the model to capture secondary effects ignored by the free streaming model. The semiempirical model displays improvement agreement with simulated results at high- Z and shows excellent extrapolation to materials and thicknesses which were not included during the calibration step. Furthermore, this work demonstrates that the semiempirical model yields accurate atomic number predictions even when the source spectra and detector response are not known exactly. In conclusion, using the semiempirical model, manufacturers can perform a simple calibration to enable more precise Z reconstruction capabilities, which has the potential to significantly improve the performance of existing dual energy radiographic systems.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2019

Sub-MeV ultra-compact linac for radioactive isotope sources replacement, non-destructive testing, security and medical applications

RadiaBeam Technologies, LLC has developed an inexpensive, hand-portable 180 keV electron accelerator to replace 57 Co radionuclide sources in Cascade Header Enrichment Monitor detectors. We used two innovative technologies in our design: a Ku-band (1 cm wavelength) magnetron, and a split accelerating structure design to reduce manufacturing costs. In this paper, we will discuss the accelerator, including X-ray convertor and accelerating structure design. The results of RF measurements of a Ku-band split structure prototype will also be reviewed. Other applications of Ku-band linacs include compact backscatter and transmission X-ray security inspection systems, as well as computed tomography (CT) systems for luggage and parcel screening. The main requirement for luggage inspection systems is that the X-ray source must be extremely compact. Further, the required energies should cover the range from 180 keV to 1 MeV. In this paper, we will discuss the linac’s energy scalability and other modifications that will enable our technology to address these applications.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2014

Leaky guided waves in generic bars: Numerical prediction and experimental validation by means of ultrasonic underwater testing

Guided Ultrasonic Waves (GUWs) are used in several industrial and civil applications for the non-destructive tests and inspection of mechanical waveguides immersed in fluids. As well known, the impedance mismatch at the fluid-structure interface causes the bulk waves traveling inside the waveguide to be partially refracted in the surrounding fluid. The leakage of bulk waves involves continuous energy radiation along the propagation direction, resulting in high attenuation rates and, consequently, reduced inspection ranges. In this work, the dispersion behaviour of leaky guided waves that propagate in immersed waveguides of general cross-section is investigated. To this end, a Semi-Analytical Finite Element (SAFE) method coupled with a 2.5D Boundary Element method (BEM) is used to extract the wave dispersion equation. The proposed formulation avoids the well known limitations of analytical methods in treating complex geometries as well as those of Finite Element-based methods in representing propagation processes in unbounded domains. Numerical and experimental results are presented, in which the dispersion curves are extracted for different bars of arbitrary shape immersed in water. The results obtained in this paper can be useful for the design of testing conditions in practical applications and to tune experimental set up.

42 ENGINEERING↗

DOE OSTI2014

Stacking fault induced tunnel barrier in platelet graphite nanofiber

A correlation study using image inspection and electrical characterization of platelet graphite nanofiber devices is conducted. Close transmission electron microscopy and diffraction pattern inspection reveal layers with inflection angles appearing in otherwise perfectly stacked graphene platelets, separating nanofibers into two domains. Electrical measurement gives a stability diagram consisting of alternating small-large Coulomb blockade diamonds, suggesting that there are two charging islands coupled together through a tunnel junction. Based on these two findings, we propose that a stacking fault can behave as a tunnel barrier for conducting electrons and is responsible for the observed double-island single electron transistor characteristics.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

DOE OSTI2015

Monitoring system for the quality assessment in additive manufacturing

Additive Manufacturing (AM) refers to a process by which a set of digital data -representing a certain complex 3dim design - is used to grow the respective 3dim real structure equal to the corresponding design. For the powder-based EOS manufacturing process a variety of plastic and metal materials can be used. Thereby, AM is in many aspects a very powerful tool as it can help to overcome particular limitations in conventional manufacturing. AM enables more freedom of design, complex, hollow and/or lightweight structures as well as product individualisation and functional integration. As such it is a promising approach with respect to the future design and manufacturing of complex 3dim structures. On the other hand, it certainly calls for new methods and standards in view of quality assessment. In particular, when utilizing AM for the design of complex parts used in aviation and aerospace technologies, appropriate monitoring systems are mandatory. In this respect, recently, sustainable progress has been accomplished by joining the common efforts and concerns of a manufacturer Additive Manufacturing systems and respective materials (EOS), along with those of an operator of such systems (MTU Aero Engines) and experienced application engineers (Carl Metrology), using decent know how in the field of optical and infrared methods regarding non-destructive-examination (NDE). The newly developed technology is best described by a high-resolution layer by layer inspection technique, which allows for a 3D tomography-analysis of the complex part at any time during the manufacturing process. Thereby, inspection costs are kept rather low by using smart image-processing methods as well as CMOS sensors instead of infrared detectors. Moreover, results from conventional physical metallurgy may easily be correlated with the predictive results of the monitoring system which not only allows for improvements of the AM monitoring system, but finally leads to an optimisation of the quality and insurance of material security of the complex structure being manufactured. Both, our poster and our oral presentation will explain the data flow between the above mentioned parties involved. A suitable monitoring system for Additive Manufacturing will be introduced, along with a presentation of the respective high resolution data acquisition, as well as the image processing and the data analysis allowing for a precise control of the 3dim growth-process.

36 MATERIALS SCIENCE↗

DOE OSTI2015

A study on laser-based ultrasonic technique by the use of guided wave tomographic imaging

Guided wave tests are impractical for investigating specimens with limited accessibility and coarse surfaces or geometrically complicated features. A non-contact setup with a laser ultrasonic transmitter and receiver is the classic attractive for guided wave inspection. The present work was done to develop a non-contact guided-wave tomography technique by laser ultrasonic technique in a plate-like structure. A method for Lam wave generation and detection in an aluminum plate with a pulse laser ultrasonic transmitter and a Michelson interferometer receiver has been developed. In the images obtained by laser scanning, the defect shape and area showed good agreement with the actual defect. The proposed approach can be used as a non-contact-based online inspection and monitoring technique.

36 MATERIALS SCIENCE↗