Abstract: Methods for anomaly detection in additive manufacture using meltpool monitoring are disclosed. A method includes obtaining a process model representative of an object to be generated through additive manufacture. The method also includes generating, based on the process model and using a hybrid machine-learning model, an instruction for generating the object through additive manufacture. Another method includes generating a layer of an object, and taking a reading relative to the generation of the layer. The other method also includes updating, based on the reading and using a hybrid machine-learning model, a process model, the process model representative of the object. The other method also includes generating, based on the updated process model and using the hybrid machine-learning model, an instruction for generating a subsequent layer of the object through additive manufacture. Related systems and devices are also disclosed.

Abstract: An ultrasonic transducer is provided. The ultrasonic transducer can be configured for flow metering applications and can include a head mass, a tail mass, and a spanning element joining the head mass with the tail mass. At least one cavity can be created in the head mass, tail mass, or spanning element using additive manufacturing. A method of manufacturing is also provided. The method of manufacturing can include forming a head mass utilizing a first process of additive manufacturing. The method of manufacturing can also include forming a tail mass utilizing a second process or additive manufacturing. The method of manufacturing can further include joining the head mass and the tail mass by a spanning element.

Abstract: An apparatus and method of embedding an optical fiber within a substrate. The apparatus includes a bonding device and a conveyance device. The bonding device bonds a foil layer to the substrate to seal the optical fiber within a groove of the substrate. The conveyance device moves the substrate and the bonding device relative to each other. Relative motion between the substrate and the bonding device draws the optical fiber into the groove and the foil layer over the optical fiber at a collection point.

Abstract: A sensor and a method of manufacture of a sensor. The sensor includes a body having a groove therein, a first optical fiber and second optical fiber disposed in the groove, and a first layer and second layer bonded in the groove. The groove is formed in the body of the sensor. The first optical fiber is deposited in the groove. The first layer is bonded in the groove to form a first chamber in which the first optical fiber is disposed. The second optical fiber is disposed in the groove. The second layer is bonded in the groove to form a second chamber in which the second optical fiber is disposed.

Abstract: A system and a method of carbon capture. The system includes a volume having a gas mixture therein, an optical fiber and a processor. The gas mixture includes carbon dioxide as a component. The optical fiber has a coating sensitive to carbon dioxide to generate a strain on the optical fiber. The processor is configured to adjust an operating parameter of the system based on a presence of the carbon dioxide determined using the optical fiber.

Abstract: A buffer rod for an acoustic measurement device including a ceramic nonmetallic body, a window plate disposed at one longitudinal end of the body, an opposite end of the body configured to interact with a transducer.

Abstract: A sensor system, including: a dielectric material on a part body; and a sensor on the dielectric material, the sensor configured to provide impedance, capacitance, and resistance values and to alter one or more of the impedance, capacitance and resistance values responsive to a stress applied to the part body. Also disclosed is a method of making and a method of using the sensor system.

Abstract: A printed circuit board (PCB) including a rigid dielectric layer having a curved geometry, and a conductive layer attached to the dielectric layer. A method for making a printed circuit board (PCB) including depositing a layer of dielectric material onto a surface, curing and sintering the material on the surface, depositing a first layer of conductive material on the layer of dielectric material, and depositing a second layer of conductive material on the first layer of conductive material, the second layer being thinner in cross section than the first layer. A system for producing a curved rigid PCB including a housing, a build platform disposed in the housing, a mobile robotic depositor disposed upon the build platform, and a print head disposed in the housing and in printing proximity to the build platform, the head having a plurality of deposition nozzles and a laser.

Abstract: A method of manufacturing is provided. The method can include determining a cross-sectional shape of an object to be inspected using a sensor configured with a sensor coil. The method can also include providing a substrate having a profile matching the cross-sectional shape of the object. The method can further include applying a dielectric material to the substrate in a patter matching a shape of the sensor coil. The method can also include forming a first layer of a first material on the dielectric material by sputtering particles of the first material on the dielectric material in the pattern and forming additional layers of the first material atop the first layer by iteratively depositing the additional layers in the pattern via an additive manufacturing technique. A sensor including a sensor coil formed via the method is also provided.

Abstract: A sensor having thermal stability at greater than 900° C., including a sensor body comprising an energy harvesting thermal electric generator, a heat sink in thermally conductive contact with the body, and a conductor electrically attached to the body, the conductor surrounded by a ceramic dielectric material. A borehole system including a borehole in a subsurface formation, a sensor disposed in the borehole.

Abstract: An ultrasonic transducer is provided. The ultrasonic transducer can be configured for flow metering applications and can include a head mass, a tail mass, and a spanning element joining the head mass with the tail mass. At least one cavity can be created in the head mass, tail mass, or spanning element using additive manufacturing. A method of manufacturing is also provided. The method of manufacturing can include forming a head mass utilizing a first process of additive manufacturing. The method of manufacturing can also include forming a tail mass utilizing a second process or additive manufacturing. The method of manufacturing can further include joining the head mass and the tail mass by a spanning element.

Abstract: A method of forming a piezoelectric device may include depositing a sol-gel film over a substrate and curing the sol-gel film by impinging light onto an exposed surface of the sol-gel film to form a piezoelectric ceramic element. The method may produce a piezoelectric composite material including at least two piezoelectric ceramic pillars over the substrate. The at least two piezoelectric pillars may include at least one layer. The at least one layer having a gradient density, such that a first portion of the at least one layer proximate the substrate has a density lower than a second portion that is located a greater distance from the substrate than the first portion. The piezoelectric composite material may further include a resin separating the at least two piezoelectric ceramic pillars.

Abstract: A method of designing and forming a piezoelectric ceramic crystal integrating an impedance matching region and a backing region. The method includes receiving one or more required operating parameters of the piezoelectric ceramic crystal for an application, iteratively modeling and simulating performance of one or more materials, structures, and gradients to utilize within the piezoelectric ceramic crystal, identifying at least one material, structure, or gradient that exhibits predicted performance that at least substantially achieves the one or more required operating parameters of the piezoelectric ceramic crystal, outputting a design of the piezoelectric ceramic crystal, and forming the piezoelectric ceramic crystal via one or more additive manufacturing processes.

Abstract: A method of forming a high temperature sensor includes preparing a substrate having a surface from an electrically insulative material having a first coefficient of thermal expansion (CTE), preparing an electrical conductor from a metal material having a second CTE that is different from the first CTE, and creating an interface between the electrical conductor and the substrate with a CTE blending medium that is provided between the substrate and the electrical conductor. The CTE blending medium accommodates differing thermal expansion rates of the substrate and the electrical conductor at temperatures of at least 700° C.

Abstract: An acoustic generator including a piezoelectric crystal, an impedance matching layer directly bonded to the crystal with Van der Waals forces.

Abstract: Acoustic impedance matching devices and related methods are disclosed. An acoustic impedance matching device includes a first face for facing an acoustic transducer, a second face opposite the first face, and a lattice structure between the first face and the second face. The second is face curved to at least substantially conformally engage an inner surface of a tubing. An effective acoustic impedance of the lattice structure substantially matches a transducer acoustic impedance of the acoustic transducer to a tubing acoustic impedance of the tubing. A material acoustic impedance of a material of the lattice structure is greater than the effective acoustic impedance.

Abstract: A method of forming a high temperature sensor includes preparing a substrate having a surface from an electrically insulative material having a first coefficient of thermal expansion (CTE), preparing an electrical conductor from a metal material having a second CTE that is different from the first CTE, and creating an interface between the electrical conductor and the substrate with a CTE blending medium that is provided between the substrate and the electrical conductor. The CTE blending medium accommodates differing thermal expansion rates of the substrate and the electrical conductor at temperatures of at least 700° C.

Abstract: An acoustic matching material for gas measurement including a matrix material having an acoustic impedance and an acoustic impedance reduction material, having an acoustic impedance lower than the acoustic impedance of the matrix material, the acoustic impedance reduction material being dispersed in the matrix material to create an acoustic impedance graduation through a thickness of the matching material.

Abstract: A sensor system, including: a dielectric material on a part body; and a sensor on the dielectric material, the sensor configured to provide impedance, capacitance, and resistance values and to alter one or more of the impedance, capacitance and resistance values responsive to a stress applied to the part body. Also disclosed is a method of making and a method of using the sensor system.

Abstract: A method of additive manufacturing may include disposing a layer of a powder material on a surface of a build platform of an additive manufacturing apparatus. The method may also include placing a compaction platform comprising one or more transducers in contact with an upper surface of the layer of the powder material. The method may additionally include activating at least one transducer of one or more transducers of the compaction platform of the compactor to densify a portion of the layer of the powder material below the at least one transducer while at least the weight of the compaction platform applies a normal force to the layer of the powder material. Related systems for densifying additively manufactured components are also described.