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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 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Effects of Coatings on Water Intrusion and Strain Gauge Durability in Submerged Fatigue Conditions: Preprint

Marine energy structures are typically made using composite materials and are repeatedly loaded by currents and waves. Submersion and repeated loading lead to two environmental effects: moisture intrusion and mechanical fatigue. To understand the combined effects of moisture intrusion and mechanical fatigue on marine energy structures, submerged fatigue testing can be used. Submerged fatigue testing often requires submerged instrumentation to validate component manufacturing methods and models. Measuring strain is critical for understanding marine energy component loads. One common method for measuring strain is by using foil strain gauges, but the durability of strain gauges in submerged fatigue conditions was not well-understood. To increase strain gauge durability and protection from contamination, delamination, and water intrusion, strain gauge coatings may be applied over strain gauges and wire connections. In this study, strain gauges were adhered to composite coupons, coated, and mechanically tested in a water tank. Cycles to composite failure, cycles to strain gauge failure, strains, and strain gauge failure modes were used to measure the effects of strain gauge coatings on composite fatigue life and strain gauge durability. The methods developed and measurements taken at the coupon scale in this study will be used to inform methods and designs for subsequent submerged subcomponent testing, full-scale testing, and standards development. The benefits of designing marine energy structures to informed standards and designs are decreased lifetime costs and increased reliability and energy production, ultimately leading to a sustainable and low-carbon energy system.

composite fatigue testing↗
DOE OSTI2025

M3AS-25IN1002073: Analysis of data from irradiation testing of printed strain gauges in prototypic nuclear environments

Advancement in additively manufactured strain gauges help address critical technology gaps to accurately monitor real-time materials behavior in reactor experiments. This is critical as it provides data to inform predictive models and simulations that enhance the development of reactors and fuel cycle systems. In this report, additively manufactured strain gauges are exposed to a neutron irradiation environment at the Ohio State University Research Reactor. This report goes over a 2-week campaign for neutron irradiating printed resistive strain gauges and capacitive strain gauges. These results complement the prior separate effects (i.e., mechanical strain, temperature, etc.) testing that were performed on these additive manufactured sensors and presented in prior milestone reports. These results also help progress our understanding of their usage in harsh environment applications. The outcome of developing advanced sensing and instrumentation capabilities plays an important role in increasing the safety, reliability, and energy efficiency of both next-generation and existing nuclear reactors.

36 - MATERIALS SCIENCE↗
DOE OSTI2024

Effects of Strain Gauge Coatings on Water Intrusion in Submerged Composite Coupon Testing

Marine energy structures are typically made using composite materials and are repeatedly loaded by currents and waves. Submersion and repeated loading lead to two environmental effects: moisture intrusion and mechanical fatigue. To understand their combined effects, submerged fatigue testing can be used. Submerged fatigue testing often requires submerged instrumentation to validate component manufacturing methods and models. Strain measurements are critical for understanding marine energy component loads. One common method for measuring strain is by using foil strain gauges, but the durability of strain gauges in submerged fatigue conditions is not well-understood. To increase strain gauge durability and protection from contamination, delamination, and water intrusion, strain gauge coatings may be applied over strain gauges and wire connections. In this study, strain gauges were adhered to composite coupons, coated, and mechanically tested in a water tank. Cycles to composite failure, cycles to strain gauge failure (SGF), strains, and SGF modes were used to measure the effects of strain gauge coatings on composite fatigue life and strain gauge durability. The coatings did not have significant effects on composite fatigue life or strain gauge durability. The methods developed and measurements taken at the coupon scale in this study will be used to inform methods and designs for subsequent submerged subcomponent testing, full-scale testing, and standards development. The benefits of designing marine energy structures to informed standards and designs are decreased lifetime costs and increased reliability and energy production, ultimately leading to a sustainable and low-carbon energy system.

composite materials↗
DOE OSTI2024

Application of printed strain gauges in prototypical nuclear reactor conditions

This report discusses the current development and testing of additively manufactured temperature sensors and resistive/ capacitive strain gauges. This has potential to improve the sensor design and manufacturing techniques to meet the requirements of in-pile monitoring of mechanical properties and structural health of materials and specimens in current and advanced nuclear test reactors (i.e., in terms of environment conditions, sample geometry, and materials compatibility). The developmental additively manufactured strain gauges are exposed to separate effects testing (i.e., mechanical strain (up to 1000 µe), high temperature (up to 700 °C)) to determine environmental factors that affect the performance of the strain gauge. The robustness and integrity of a printed strain gauge layer exposed to a molten salt environment for up to 500 hours was evaluated, with the goal of assessing material compatibility of printed strain sensors for instrumented surveillance test articles in molten salt reactors. In addition, sensor qualification methodologies are further developed for determining the reliability and robustness at the interface of the additively manufactured strain gauge materials.

36 - MATERIALS SCIENCE↗
DOE OSTI2025

Propagation of Noise Uncertainty Through Virtual Strain Gauge Formulations for 2D Digital Image Correlation

The effect of displacement uncertainty is examined on 2-dimensional strain, calculated using linear surfaces fitted to the displacement field. A classical engineering error propagation method is used to calculate uncertainty in Green-Lagrangian strain calculations. The derived uncertainty is compared to a Monte Carlo simulation and discrepancies under 2% are seen between these two methods. The effect of virtual strain gauge size, displacement uncertainty, and boundaries on the region of interest on the strain uncertainty are considered. Here, an exponential decay relationship is observed between strain uncertainty and virtual strain gauge size, while a linear relationship is seen between strain and displacement uncertainty. For boundaries in the region of interest, strain uncertainty is affected by the reduced number of points available to perform the regression.

42 ENGINEERING↗
DOE OSTI2025

Tunneling Barrier-Integrated Gold Nanofilms for Negative Strain Gauging with Near-Zero Energy Consumption

Wireless strain sensors with minimal power needs are essential for long-term monitoring in energy-limited environments. We present a soft tunneling barrier-integrated gold thin film for negative strain sensing with near-zero energy consumption. The device features a strain-induced transition from an insulating to a metallic state, increasing conductivity by 9 orders of magnitude under a controlled strain. It consists of Au-PDMS-Au nanofilm layers, where the Au structures are near the percolation threshold and the PDMS layer acts as a tunneling barrier. Under strain, thinning due to the Poisson effect lowers the barrier’s potential height, enabling electron tunneling and forming an electrical path. Further, with a standby power consumption of ~10 –5 mW over 10 6 times lower than conventional sensors (~12.5 mW), this device is ideal for real-time, long-term stationary structural monitoring in multiple locations.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2025

Strain-Based Assessment of Shale Caprock during Cyclic Underground Hydrogen Storage

Successful large-scale underground hydrogen storage (UHS) in depleted gas reservoirs depends on the integrity of the overlying caprock to prevent hydrogen loss during cyclic injection and depletion. Prior studies on crushed Marcellus shale, a potential caprock, indicate that cyclic hydrogen injection and depletion induces microstructural changes, increasing porosity and permeability. However, the extent of these changes in intact shale remains unclear. This study presents a strain-based experimental approach to quantify volumetric strain evolution in intact Marcellus shale matrix under unconstrained stress conditions. A quadrant-shaped shale sample without visible fractures underwent eight hydrostatic pore-pressure cycles (injection to 1500 psi and depletion to 500 psi in 250 psi steps). Linear strain gauges measured strain in three orthogonal directions. Results indicate progressive plastic strain accumulation, leading to an ∼12% increase in matrix porosity after eight cycles, with an estimated 19% increase after 30 cycles. This porosity increase follows a logarithmic trend, suggesting a diminishing effect in later cycles. Additionally, permeability and diffusive mass flux are projected to rise by ∼70% over 30 cycles, enhancing hydrogen migration risk. The shale matrix also exhibited mechanical stiffening over successive cycles, limiting large-scale deformation but not preventing porosity enhancement. A new parameter, α, was introduced to characterize shale sensitivity to cyclic loading, aiding UHS caprock assessments. These findings underscore the necessity of incorporating cyclic loading effects in UHS site selection and operational strategies to ensure long-term storage integrity.

08 HYDROGEN↗
DOE OSTI2025

Machine Learning Analysis of Temperature-Strain Relationships for Structural Health Monitoring of Pipes: Self-powered wireless sensor system for health monitoring of liquid-sodium cooled fast reactors

This report presents machine learning (ML) analysis of temperature-strain relationships for structural health monitoring of nuclear reactor stainless steel (SS) pipes with the strain gauge sensor directly printed on the pipe with a 3D conformal aerosol jet printer. We investigate correlations for two sensor pairs installed on the same SS304 pipe: commercial K-type thermocouple with a printed gold strain gauge (TC3-SG3), and commercial K-type thermocouple with commercial Kyowa strain gauge (TC0-SG0). The temperature ranges for the sensor pairs TC0-SG0 and TC3-SG3 are 20.00°C to 266.37°C and 39.95°C to 219.28°C respectively. ML algorithms in this study include Linear Regression (baseline method), Ridge Regression, Lasso Regression, and Gradient Boosting. Performance evaluation metrics include Root Mean Square Error (RMSE), Mean Square Error (MSE), Mean Absolute Error (MAE), R 2 Score, and Explained Variance. Using advanced feature engineering techniques, we extracted 27 temperature-based features and 30 strategic inclusion features. The best performance was obtained with the Gradient Boosting method, which achieves prediction accuracy of R 2 = 0.9999 and RMSE = 7.69 μStrain for TC0-SG0, and R 2 = 0.9998 and RMSE = 18.03 μStrain for TC3-SG3. While the temperature-strain correlations are weaker for the gauge directly printed on the pipe than for the commercial strain gauge, deployment-ready performance exceeding industry standards is achieved for both sensor pairs.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2026

Enabling In-Core Strain Measurement: Printed Sensors for Advanced Reactors

Advances in nuclear energy systems require an improved understanding of fuels, cladding, and structural materials; however, the extreme environmental conditions at irradiation test facilities often limit mechanical property evaluation to post-irradiation examination. In-situ monitoring techniques can accelerate materials qualification by providing direct insight into real-time material behavior during irradiation testing. Additively manufactured (AM) strain gauges offer a compact, material-compatible alternative to commercial sensors, particularly where space constraints, attachment limitations, or material compatibility requirements complicate conventional sensor use. This poster presents an overview of the development and testing of AM strain gauges in nuclear-relevant environments, demonstrating their potential to enhance structural health monitoring capabilities during irradiation experiments.

36 - MATERIALS SCIENCE↗
DOE OSTI2024

In-Situ Blade Strain Measurements and Fatigue Analysis of a Cross-Flow Turbine Operating in a Tidal Flow

Cross-flow turbines (CFTs) are inherently unsteady devices with regards to operating principle and loading. By improving our understanding of the dynamic loading on these turbines, we hope to better inform CFT design, improve survivability, and reduce overall costs. The University of New Hampshire (UNH) and the National Renewable Energy Laboratory (NREL) collaborated on a project to instrument and test a four-bladed New Energy Corp. vertical axis cross-flow turbine in a real tidal flow. One blade from the 3.2 m diameter x 1.7 m height turbine was instrumented with eight full-bridge strain gauges along the span of the blade. The turbine was then deployed at the UNH-Atlantic Marine Energy Center (AMEC) Tidal Energy Test Site in Portsmouth, NH. Time-synchronized measurements of blade strain, inflow, thrust, rotational speed, and electrical output were obtained to characterize blade loading under various conditions. The blade strain was examined to assess the dynamic loading and conduct a fatigue analysis on the device.

blade strain↗
DOE OSTI2025

Field validation of dynamic mechanical torque measurements using fiber-optic strain sensors for geared wind turbines

Abstract Accurate knowledge of the mechanical loads of wind turbine gearboxes has become essential in modern, highly loaded gearbox designs, as maintaining or even improving gearbox reliability with increasing torque density demands is proving to be challenging. Unfortunately, the traditional method of measuring dynamic mechanical torque using strain gauges placed on the outer surface of a rotating shaft and transmitting the resulting signal is unsuitable for serial deployment due to technical and economic constraints. An alternative method based on fiber-optic strain sensors placed on the stationary outer surface of the gearbox ring gear has been proposed. Like shaft torsion, the radial deformation of the ring gear is proportionate to the rotor torque. Placing the sensors on a stationary component is a cost-effective alternative for serial implementation because the need for complex and expensive data transfer via wireless transmission or a slip ring is eliminated. In this paper, we present the results of an extensive field experiment conducted to evaluate the torque measurement accuracy of this novel sensing solution installed on the gearbox of a Gamesa G97 2-MW wind turbine at the National Renewable Energy Laboratory’s Flatirons Campus. Torque measurements derived from fiber-optic strain sensors placed on the ring gear of the planetary stage are compared to conventional torque measurements from strain gauges placed on the main shaft. Two different torque estimation data processing methods were evaluated, with the method based on operational deflection shapes providing the most accurate results with an average normalized root mean square error below 0.7% for a load revolution distribution analysis. The effect of operating conditions on the torque estimate was also investigated, and the third planet-passing operational deflection shape was found to be the least sensitive to nontorque load-related effects. The fiber-optic strain sensors’ successful operation during the complete test campaign has demonstrated a robust and accurate solution for fleet-wide enhanced gearbox remaining useful life estimation.

17 WIND ENERGY↗
DOE OSTI2025

Field Validation of Dynamic Mechanical Torque Measurements for Geared Wind Turbines

Accurate knowledge of the mechanical loads of wind turbine gearboxes has become essential in modern, highly loaded gearbox designs, as maintaining or even improving gearbox reliability with increasing torque density demands is proving to be challenging. Unfortunately, the traditional method of measuring dynamic mechanical torque using strain gauges placed on the outer surface of a rotating shaft and transmitting the resulting signal is unsuitable for serial deployment due to technical and economic constraints. An alternative method based on fiber-optic strain sensors placed on the stationary outer surface of the gearbox ring gear has been proposed. Like shaft torsion, the radial deformation of the ring gear is proportionate to the rotor torque. Placing the sensors on a stationary component is a cost-effective alternative for serial implementation because the need for complex and expensive data transfer via wireless transmission or a slip ring is eliminated. In this paper, we present the results of an extensive field experiment conducted to evaluate the torque measurement accuracy of this novel sensing solution installed on the gearbox of a Gamesa G97 2-MW wind turbine at the National Renewable Energy Laboratory's Flatirons Campus. Torque measurements derived from fiber-optic strain sensors placed on the ring gear of the planetary stage are compared to conventional torque measurements from strain gauges placed on the main shaft. Two different torque estimation data processing methods were evaluated, with the method based on operational deflection shapes providing the most accurate results with an average normalized root mean square error below 0.7% for a load revolution distribution analysis. The effect of operating conditions on the torque estimate was also investigated, and the third planet-passing operational deflection shape was found to be the least sensitive to nontorque load-related effects. The fiber-optic strain sensors' successful operation during the complete test campaign has demonstrated a robust and accurate solution for fleet-wide enhanced gearbox remaining useful life estimation.

17 WIND ENERGY↗
DOE OSTI2024

Elastic-plastic conductor damage evaluation at over 0.4% strain using a high-stress REBCO coil

Abstract Recent reports on screening current stress simulations of high-field REBCO magnets frequently present peak stresses over 1 GPa. However, this result is probably an unrealistic artifact of purely elastic calculations, considering the macroscopic yield and fracture stresses of approximately 900 MPa and less than 1.1 GPa for Hastelloy substrate-coated conductors. Here, we evaluate elastic-plastic conductor damage at over 0.4% strain using a high-stress REBCO coil exposed to a high field to explore this elastic-plastic regime. The coil was located off-center in a low-temperature superconductor magnet so as to induce a significant screening current in the enhanced radial field. Voltage taps, a Hall sensor, and two strain gauges were used for the instrumentation. We obtained strains exceeding 0.4% near the outward edge during the coil current charge from 350 A to 390 A, where the coil was exposed to external axial and radial magnetic fields of 13 T and 0.5 T. Post mortem results showed wavy plastic deformation, electrical damage, and REBCO defects. An elastic-plastic simulation reproduced the measured strains and predicted that ∼1 GPa stress is sufficient to induce ∼0.9% strain, thus validating our initial concerns with purely elastic models. This paper provides our experimental and simulation results.

Bang, Jeseok (ORCID:0000000247616334)↗
DOE OSTI2024

Dynamic Modeling and Characterization of Nuclear-grade Graphite

Idaho National Labs serves as the spearhead for many innovative energy solutions to the world's energy crisis. One such solution is the INL's Microreactor which is designed to deploy to extreme/remote environments where other sources of power are either unavailable or unreliable. In order to best design these energy solutions for their operational environments, it is crucial to understand how the design, components, and materials will respond to the environmental conditions. One key material in these innovative designs is a nuclear-grade graphite known as PCEA. This study examines the behavior of PCEA graphite under dynamic loading, similar to that which may occur in extreme environments. The objective is to characterize the dynamic behavior and produce an accurate, reliable constitutive model suitable for use in simulation tools such as INL's MOOSE. Graphite specimens were tested using a Split Hopkinson Pressure Bar (SHPB) to administer the dynamic compressive load. The SHPB was charged at various pressures to produce a range of strain rates on the material in compression. Data was acquired via strain gauges on the SHPB setup, from which stress, strain, and time data were collected. Analysis revealed the stress-strain behavior of the material as well as insights into the material behavior's relationship to strain rate. Further work must continue to characterize the various other dynamic behaviors of the material which will combine to create a substantially trustworthy constitutive model for this grade of nuclear-grade graphite. Ultimately, this will allow for realistic simulation of the material in reactor designs, allowing for prediction of design weaknesses and leading to improved designs for increased resilience, security, and reliability.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Improving high temperature resilience of fiber sensor embedded smart components through laser shock peening

This study explores the use of laser shock peening (LSP) to enhance material properties and high-temperature performance of fiber-sensor-fused smart parts fabricated by additive manufacturing (AM) methods. Using embedded fiber sensors as distributed strain gauges, the study demonstrates that LSP can induce compressive strains of up to 130 µε on fiber embedded 1-mm below metal surfaces. The electron backscatter diffraction (EBSD) analysis shows that, with optimized LSP parameters, the metallic matrix undergoes substantial microstructural refinement, resulting in denser structures. Thermal cycling tests showed that the LSP process can increase fiber slippage temperatures by more than 50 °C. This work shows that the LSP process is an effective room-temperature process for enhancing both surface quality and increasing fiber slippage threshold under both thermal and mechanical stress.

Zhong, Shuda [University of Pittsburgh, PA (United↗
DOE OSTI2026

SAVY-4000 Finite-Element Drop Test Analysis

PFE Auxiliary Systems conducted drop testing on SAVY-4000 containers to evaluate structural response under 12-foot drop conditions. In support of that effort, a finite-element modeling capability was developed to simulate drop response across multiple container sizes and impact orientations. The purpose of this work was to provide a consistent analysis framework that could support interpretation of testing, compare response trends across multiple configurations, and generate quantities of interest for later comparison with experimental data. More broadly, the analysis and testing were intended to assess whether the containers continued to perform their primary function after a 12-foot drop, namely maintaining structural integrity and containment of the contents. The modeling approach combined an implicit preload analysis with an explicit drop simulation so that each drop event began from a mechanically realistic assembled condition, including compression of the silicone O-ring. Separate models were developed for 2-quart, 5-quart, 12-quart, and 10-gallon containers. The results were evaluated in terms of strain-gauge response, collar-lid gap behavior, and accumulated plastic strain. In addition, parametric studies were performed on the 2-quart container to assess sensitivity to O-ring stiffness, friction, canister thickness, geometry tolerance, and mesh density. The simulations showed that predicted drop responses depended strongly on both container size and drop orientation. Gap metrics identified cases in which the predicted collar-lid opening exceeded the nominal O-ring cross-section threshold, while plastic strain metrics identified localized regions of elevated permanent deformation. Parametric studies showed that the predicted response was especially sensitive to the assumed O-ring stiffness and contact friction, while the geometry tolerance study produced smaller changes in the cases examined. The main value of this work was that it established a repeatable modeling and simulation workflow to support drop-test implementation, evaluate effects of future configuration changes, and understand modeling assumptions that most influenced predicted response. At the current stage, the results were viewed as preliminary model predictions rather than validated predictions. The next step would be to compare drop-test data to the model so that predictive values of the workflow could be refined and used with greater confidence to assess whether the containers maintained structural integrity and containment of the contents after a 12-foot drop.

42 ENGINEERING↗
DOE OSTI2026

Initial Feasibility Assessment and Broader Strategy Development for Fiber Integration via Advanced Manufacturing

Structural health monitoring is critical for ensuring the operational safety and cost-competitiveness of the developing advanced reactor designs. The extreme operational envelopes of these advanced architectures, having operating temperatures ranging 400°C–1,000°C and heightened displacement damage doses, render conventional commercially available piezoelectric transducers and resistive strain gauges unviable. Optical fiber sensors present an attractive solution for advanced radiation-hardened instrumentation due to their high thermal stability and distributed sensing capabilities. However, their deployment in embedded applications can be hindered by the severe thermomechanical strain driven by the coefficient of thermal expansion mismatch between fused silica glass and structural metal alloys like stainless steel (e.g., SS316L).

36 MATERIALS SCIENCE↗