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At least 235 records · Page 13
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Quantifying Trapped Powder in Electron Beam Powder Bed Fusion

Abstract Electron beam powder bed fusion (PBF-EB) shows great potential for manufacturing complex parts including those with internal cavities for heat exchanger, manifold systems, or energy absorption purposes. PBF-EB allows for the manufacture of channel geometries without the need for support structures. Due to the nature of the powder spreading process, powder feedstock is often trapped in intentionally manufactured cavities. This trapped powder can often be difficult to remove and can disturb the intended flow of fluid through the cavity or damage downstream components in its use case. These trapped powder particles present a risk of contamination and component failure if not completely evacuated. Ti6Al4V is a choice material for aerospace applications due to its high strength to weight ratio and its composition as a nonferrous metal; however, in weight sensitive applications excess entrapped powders or powders loosely attached to the surface could cause undesirable weight increases. The inherent spreading process of PBF-EB is different than laser powder bed fusion (PBF-LB) in its operational temperature, sintering. In addition, PBF-EB is less commonly studied in literature compared to its PBF-LB counterpart, and as a result the complexity of the semi-sintered powder and its spreading behavior are not well understood. Prior work has investigated the difficulty in removing trapped powder from PBF-EB, but these studies do not address how to quantify the amount of trapped powder in the cavity. Thus, an accurate method to measure the amount of trapped powder in the cavity must be investigated. In this work, Ti6Al4V coupons were manufactured with horizontal and vertical cavities of three different sizes. Archimedes testing allows for the determination of density differences caused by porosity and trapped powders by measuring mass and volumetric dispersion. Computed tomography (CT) is well suited for segmenting the internal structure and features of a part and has been studied for applications including voids, porosity, and dross. Thus, CT was explored as a method for evaluating trapped powder content in this work. The volumetric representation of the segmentation of the reconstructed CT volume can vary greatly depending on the input filter and thresholding methods. In this study, four different types of segmentation approaches were evaluated to determine the best approach for segmenting the volume as compared to an operator labeled ground truth. The percentage density results from the Archimedes testing were compared to the volumetric percent density from the computed tomography approach. Differences in packing density between two different internal channel features were investigated. Overall, this work sought to validate the use of computed tomography for the detection of trapped powders and present a framework for volumetric segmentation.

Johnstone, Brian↗
NASA NTRS1984

Experimental observations of nonlinearly enhanced 2omega-UH electromagnetic radiation excited by steady-state colliding electron beams

Counterstreaming large-diameter electron beams in a steady-state laboratory experiment are observed to generate transverse radiation at twice the upper-hybrid frequency (2omega-UH) with a quadrupole radiation pattern. The electromagnetic wave power density is nonlinearly enhanced over the power density obtained from a single beam-plasma system. Electromagnetic power density scales exponentially with beam energy and increases with ion mass. Weak turbulence theory can predict similar (but weaker) beam energy scaling but not the high power density, or the predominance of the 2omega-UH radiation peak over the omega-UH peak. Significant noise near the upper-hybrid and ion plasma frequencies is also measured, with normalized electrostatic wave energy density W(ES)/n(e)T(e) approximately 0.01.

Intrator, T.↗
NASA NTRS1990

Measurement of the electron beam mode in earth's foreshock

High frequency electric field measurements from the AMPTE IRM plasma wave receiver are used to identify three simultaneously excited electrostatic wave modes in the earth's foreshock region: the electron beam mode, the Langmuir mode, and the ion acoustic mode. A technique is developed which allows the rest frame frequecy and wave number of the electron beam waves to be determined. It is shown that the experimentally determined rest frame frequency and wave number agree well with the most unstable frequency and wave number predicted by linear homogeneous Vlasov theory for a plasma with Maxwellian background electrons and a Lorentzian electron beam. From a comparison of the experimentally determined and theoretical values, approximate limits are put on the electron foreshock beam temperatures. A possible generation mechanism for ion acoustic waves involving mode coupling between the electron beam and Langmuir modes is also discussed.

Onsager, T. G.↗
DOE OSTI2023

Progress on an Electron Beam Profile Monitor at the Fermilab Main Injector

The current program at Fermilab involves the construction of a new superconducting linear accelerator (LINAC) to replace the existing warm version. The new LINAC, together with other planned improvements, is in support of proton beam intensities in the Main Injector (MI) that will exceed 2 MW. Measuring the transverse profiles of these high intensity beams in a ring requires non-invasive techniques. The MI uses ionization profile monitors as its only profile system. An alternative technique involves measuring the deflection of a probe beam of electrons with a trajectory perpendicular to the proton beam. This type of device was installed in MI and initial studies of it have been previously presented. This paper will present the status and recent studies of the device utilizing different techniques.

43 PARTICLE ACCELERATORS↗
DOE OSTI2023

Progress on an Electron Beam Profile Monitor at the Fermilab Main Injector

The current program at Fermilab involves the construction of a new superconducting linear accelerator (LINAC) to replace the existing warm version. The new LINAC, together with other planned improvements, is in support of proton beam intensities in the Main Injector (MI) that will exceed 2 MW. Measuring the transverse profiles of these high intensity beams in a ring requires non-invasive techniques. The MI uses ionization profile monitors as its only profile system. An alternative technique involves measuring the deflection of a probe beam of electrons with a trajectory perpendicular to the proton beam. This type of device was installed in MI and initial studies of it have been previously presented. This paper will present the status and recent studies of the device utilizing different techniques.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
NASA NTRS1999

Three-Dimensional Simulations of Electron Beams Focused by Periodic Permanent Magnets

A fully three-dimensional (3D) model of an electron beam focused by a periodic permanent magnet (PPM) stack has been developed. First, the simulation code MAFIA was used to model a PPM stack using the magnetostatic solver. The exact geometry of the magnetic focusing structure was modeled; thus, no approximations were made regarding the off-axis fields. The fields from the static solver were loaded into the 3D particle-in-cell (PIC) solver of MAFIA where fully 3D behavior of the beam was simulated in the magnetic focusing field. The PIC solver computes the time-integration of electromagnetic fields simultaneously with the time integration of the equations of motion of charged particles that move under the influence of those fields. Fields caused by those moving charges are also taken into account; thus, effects like space charge and magnetic forces between particles are fully simulated. The electron beam is simulated by a number of macro-particles. These macro-particles represent a given charge Q amounting to that of several million electrons in order to conserve computational time and memory. Particle motion is unrestricted, so particle trajectories can cross paths and move in three dimensions under the influence of 3D electric and magnetic fields. Correspondingly, there is no limit on the initial current density distribution of the electron beam, nor its density distribution at any time during the simulation. Simulation results including beam current density, percent ripple and percent transmission will be presented, and the effects current, magnetic focusing strength and thermal velocities have on beam behavior will be demonstrated using 3D movies showing the evolution of beam characteristics in time and space. Unlike typical beam optics models, this 3D model allows simulation of asymmetric designs such as non- circularly symmetric electrostatic or magnetic focusing as well as the inclusion of input/output couplers.

Kory, Carol L.↗
NASA NTRS1994

Electron beams in solar flares

A list of publications resulting from this program includes 'The Timing of Electron Beam Signatures in Hard X-Ray and Radio: Solar Flare Observations by BATSE/Compton Gamma-Ray Observatory and PHOENIX'; 'Coherent-Phase or Random-Phase Acceleration of Electron Beams in Solar Flares'; 'Particle Acceleration in Flares'; 'Chromospheric Evaporation and Decimetric Radio Emission in Solar Flares'; 'Sequences of Correlated Hard X-Ray and Type 3 Bursts During Solar Flares'; and 'Solar Electron Beams Detected in Hard X-Rays and Radiowaves.' Abstracts and reprints of each are attached to this report.

Aschwanden, Markus J.↗
NASA NTRS1981

Electron beam induced damage in ITO coated Kapton

Data for the stability of thin conductive indium tin oxide films on 0.003 inch thick Kapton substrates during exposure of the surface to electron beams are reported. The electron beam energy was 3 keV and the diameter was about 0.8 mm. Thermal effects and surface modifications are considered. For primary current greater than 0.6 microamperes, an obvious dark discoloration with diameter approximately that of the beam was produced. The structure of the discolored region was studied with the scanning electron microscope, and the findings are stated. Surface modifications were explored by AES, obtaining spectra and secondary emission coefficient as a function of time for different beam intensities. In all cases beam exposure results in a decrease of the secondary yield but because of thermal effects this change, as well as composition changes, cannot be directly interpreted in terms of electron beam dosage.

Krainsky, I.↗
NASA NTRS1988

Propagation of electron beams in space

Particle simulations were performed in order to study the effects of beam plasma interaction and the propagation of an electron beam in a plasma with a magnetic field. It is found that the beam plasma instability results in the formation of a high energy tail in the electron velocity distribution which enhances the mean free path of the beam electrons. Moreover, the simulations show that when the beam density is much smaller than the ambient plasma density, currents much larger than the thermal return current can be injected into a plasma.

Ashour-Abdalla, M.↗
NASA NTRS1978

Analysis of the interaction of an electron beam with a solar cell. I. II

The short-circuit current generated by the electron beam of a scanning electron microscope when it impinges on the N-P junction of a solar cell is known to be dependent on the configuration used to investigate the cell's response, and the situation for one specific configuration is analyzed. This configuration is the case in which the highly collimated electron beam strikes the edge of a planar junction a variable distance away from the edge of the depletion layer. An earlier treatment is generalized to encompass the ohmic contact at the back surface. The analysis employing Fourier and Wiener-Hopf techniques shows that it is impractical to determine the bulk diffusion length of a solar cell by a SEM used in the studied configuration unless the ohmic contact is partially removed.

Von Roos, O.↗
DOE OSTI2024

Electron beam characterization via quantum coherent optical magnetometry

We present a quantum optics-based detection method for determining the position and current of an electron beam. As electrons pass through a dilute vapor of rubidium atoms, their magnetic field perturbs the atomic spin's quantum state and causes polarization rotation of a laser resonant with an optical transition of the atoms. By measuring the polarization rotation angle across the laser beam, we recreate a 2D projection of the magnetic field and use it to determine the e-beam position, size, and total current. We tested this method for an e-beam with currents ranging from 30 to 110 μA. Our approach is insensitive to electron kinetic energy, and we confirmed that experimentally between 10 and 20 keV. In conclusion, this technique offers a unique platform for noninvasive characterization of charged particle beams used in accelerators for particle and nuclear physics research.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗