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Results for “laser processing”

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 289 records · Page 16
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

On the melt pool dynamic of voxel-controlled metal matrix composites via hybrid additive manufacturing: Laser powder bed fusion and ink-jetting

In this study, the effect of the addition of reinforcement nanoparticles to the 316L matrix by adopting ex-situ and in-situ method (drop on demand jetting) to produce 316L/Al 2 O 3 nanocomposite was investigated. In the ex-situ method, the Al 2 O 3 nanoparticles (NPs) were lightly mixed with 316L powder and processed by laser powder bed fusion. In the in-situ method, an ethanol-based ink containing Al 13 nanoclusters (NCs) was added to 316L powder and then processed by laser. Both ex-situ and in-situ method produced nanocomposites with Al-Si-Mn-O-enriched precipitations within the 316L matrix. The addition of NPs/NCs to the 316L matrix, altered the geometrical characteristic of the single-track melt pools. At the same laser power, with increasing the amount of Al 2 O 3 NPs and Al 13 NCs the melt pool deepened due to reduced thermal conductivity and prolonged liquid presence. Further, as a result, 316L/1 wt% Al 13 NCs deposited single track showed larger grains in comparison to 316L single track. At a high laser power of 150W, the Marangoni flow and the buoyancy force caused the nanoparticles to agglomerate and float to the top surface of tracks; therefore, the wt% fraction of precipitation was drastically reduced due to the loss of Al. The 316L/Al 2 O 3 NPs and 316L/Al 13 NCs exhibited the microhardness of 285 ± 13 HV and 293 ± 7 HV, respectively, higher than the deposited 316L single track, 265 ± 15 HV. Lastly, a hybrid LPBF+ink-jet printer was adopted to selectively change the composition of different zones by adding Al 13 NCs ink to 316L and producing a voxel-controlled metal matrix composite.

316L↗
DOE OSTI2023

Four-dimensional dynamics of multirotational transition stimulated rotational Raman scattering in air

Stimulated rotational Raman scattering in air is a powerful parasitic process that degrades high intensity laser beams and pulses propagated over significant distances. Conversely, it is used beneficially in the context of Raman lasers. Through this inelastic scattering process, laser photons are converted to higher (anti-Stokes) or lower (Stokes) energies, according to rotational mode transitions in nitrogen and oxygen diatomic molecules. The full wave-mixing problem involves numerous frequencies, and it is consistently assumed that only one rotational mode contributes to the conversion process. We instead present a dynamic 4D multirotational model that is implemented in a parallelized manner within the Virtual Beamline++ optical modeling package allowing high-resolution 4D studies. We highlight the effect that spontaneous emission plays in large and small beam-width setups, even in the highly saturating regime. The weaker transition modes play a large role in the persistent dynamics and can lead to complex spatiotemporal coupling through nonlinear competition of the modes. We highlight how and why these weaker modes persist, how the size and shape of speckle patterns depends highly on the initial beam profile, and how weaker modes can transiently become stronger as a result of such competition.

47 OTHER INSTRUMENTATION↗
DOE OSTI2021

Atomic understanding of structural deformations upon ablation of graphene

We investigate the atomic rearrangement in graphene under femtosecond pulse illumination with reactive molecular dynamics simulations and compare with ultra-fast laser ablation experiments. To model the impact of the laser pulse irradiation, heat is locally applied to a selected area of the graphene layer and the resulting structural deformation is simulated as a function of time, providing a detailed understanding of the bond breaking process under laser illumination and subsequent re-equilibration afterAQ3 the pulse is turned off. Analysis of the atomic dynamics indicates that the types of defects formed depend on the pulse energy and exposure duration. By varying the exposed area, we determine that the shape of the ablated area is not only a function of the pulse energy, but also of the beam spot size and pulse repetition. Furthermore, we apply a machine learning approach to extrapolate our simulated data to experimental length scales and reproduce the trends in ablated area as a function of temperature. Furthermore, our study provides a first step towards understanding the design parameters for graphene nano-patterning.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
NASA NTRS1979

Simulated electronic heterodyne recording and processing of pulsed-laser holograms

The electronic recording of pulsed-laser holograms is proposed. The polarization sensitivity of each resolution element of the detector is controlled independently to add an arbitrary phase to the image waves. This method which can be used to simulate heterodyne recording and to process three-dimensional optical images, is based on a similar method for heterodyne recording and processing of continuous-wave holograms.

Decker, A. J.↗
NASA NTRS1990

Comparison of UNL laser imaging and sizing system and a phase Doppler system for analyzing sprays from a NASA nozzle

Research was conducted on characteristics of aerosol sprays using a P/DPA and a laser imaging/video processing system on a NASA MOD-1 air assist nozzle being evaluated for use in aircraft icing research. Benchmark tests were performed on monodispersed particles and on the NASA MOD-1 nozzle under identical lab operating conditions. The laser imaging/video processing system and the P/DPA showed agreement on a calibration tests in monodispersed aerosol sprays of + or - 2.6 micron with a standard deviation of + or - 2.6 micron. Benchmark tests were performed on the NASA MOD-1 nozzle on the centerline and radially at 0.5 inch increments to the outer edge of the spray plume at a distance 2 ft downstream from the exit nozzle. Comparative results at two operation conditions of the nozzle are presented for the two instruments. For the 1st case studied, the deviation in arithmetic mean diameters determined by the two instruments was in a range of 0.1 to 2.8 micron, and the deviation in Sauter mean diameters varied from 0 to 2.2 micron. Severe operating conditions in the 2nd case resulted in the arithmetic mean diameter deviating from 1.4 to 7.1 micron and the deviation in the Sauter mean diameters ranging from 0.4 to 6.7 micron.

Alexander, Dennis R.↗
NASA NTRS1988

Comparison of UNL laser imaging and sizing system and a phase/Doppler system for analyzing sprays from a NASA nozzle

Aerosol spray characterization was done using a P/DPA and a laser imaging/video processing system on a NASA MOD-1 air-assist nozzle being evaluated for use in aircraft icing research. Benchmark tests were performed on monodispersed particles and on the NASA MOD-1 nozzle under identical laboratory operating conditions. The laser imaging/video processing system and the P/DPA showed agreement on calibration tests in monodispersed aerosol sprays of + or - 2.6 microns with a standard deviation of + or - 2.6 microns. Tests were performed on the NASA MOD-1 nozzle on the centerline and radially at one-half inch increments to the outer edge of the spray plume at a distance two feet (0.61 m) downstream from the exit of the nozzle. Comparative results at two operating conditions of the nozzle are presented for the two instruments. For the first case, the deviation in arithmetic mean diameters determined by the two instruments was in a range of 0.1 to 2.8 microns, and the deviation in Sauter mean diameters varied from 0 to 2.2 microns. Operating conditions in the second case were more severe which resulted in the arithmetic mean diameter deviating from 1.4 to 7.1 microns and the deviation in the Sauter mean diameters ranging from 0.4 to 6.7 microns.

Alexander, Dennis R.↗
NASA NTRS2004

An Acquisition Control for the Laser Interferometer Space Antenna

The Laser Interferometer Space Antenna (LISA) mission is a planned gravitational wave detector consisting of three spacecraft in heliocentric orbit. Laser interferometry is used to measure distance fluctuations between test masses aboard each spacecraft to the picometer level over a 5 million kilometer separation. Each spacecraft has two incoming and two outgoing laser beams for a total of six laser links. These links will have to be established sequentially at the start of the mission, and the spacecraft control systems must aim their lasers at each other with pointing motions less than 8 nanoradians per root Hertz in the frequency band 0.1-100 mHz. This paper presents a strategy for the laser acquisition process. The outgoing beam on one spacecraft is spoiled to provide a wide beam that encompasses the accuracy (noise and mounting bias) of the star tracker. The control system then takes advantage of an array of sensors with increasing sensitivity to quiet the receiving spacecraft and lock the laser. This process is carried out for each of the six links of LISA. A complete analysis and simulation of the acquisition process are presented.

Maghami, Peiman G.↗
DOE OSTI2021

Adaptive four-level modeling of laser cooling of solids

Laser cooling of rare-earth doped solids has been demonstrated across a wide range of material platforms, inspiring the development of simple phenomenological models such as the four-level model to elucidate the universal properties of laser cooling under various operating conditions. However, these models usually require the input of full absorption spectra that must be provided experimentally or by additional complicated atomic modeling. In this Letter, we propose that a four-level model, when extended to admit effective energy levels adaptive to the pumping photon energy, can accurately predict the cooling efficiency as a function of temperature and pumping frequency using only few inputs such as the absorption coefficient measured at a single frequency and temperature. Our model exploits the quasi-equilibrium properties of the excitation of rare-earth ions for the determination of the effective four energy levels. The model is validated against published experimental results for a span of materials including ytterbium/thulium-doped glass and crystals. With the verified model, we derive explicit expressions for the optimal frequency and the operating bandwidth of pumping lasers. Our model significantly simplifies the modeling process of laser cooling and is expected to stimulate further development of optical refrigeration.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
NASA NTRS1997

Gold Coating

Epner Technology Inc. responded to a need from Goddard Space Flight Center for the ultimate in electroplated reflectivity needed for the Mars Global Surveyor Mars Orbiter Laser Altimeter (MOLA). Made of beryllium, the MOLA mirror was coated by Epner Technology Laser Gold process, specially improved for the project. Improved Laser Gold- coated reflectors have found use in an epitaxial reactor built for a large semiconductor manufacturer as well as the waveguide in Braun-Thermoscan tympanic thermometer and lasing cavities in various surgical instruments.

Source record↗
NASA NTRS2020

Miniaturized Laser Absorption Spectrometer for Combustion Calorimetry and Process Monitoring

A miniaturized tunable laser absorption spectrometer capable of measuring gas-phase concentrations of CO, CO2, and O2 has been developed for operation in spacecraft environments. As part of the Spacecraft Fire Safety Demonstration (Saffire) project, we previously demonstrated the Combustion Product Monitor (CPM) instrument to characterize pyrolysis of relevant test materials in low gravity aboard a transfer vehicle returning from low Earth orbit. Here, we adapted the CPM instrument design to achieve detection of CO, CO2, and O2 with improved minimum detection limits and dynamic range as well as reduced instrument size and power. The instrument can be operated in either an open or sealed configureation, allowing for ambient gas composition measuremnts or in-line monitoring of gas streams. By accurately monitoring CO, CO2, and O2 with broad pressure/temperature calibration and response time on the order of 1 s, the instrument can be used to characterize the dynamics of combustion reactions in a variety of environments.

Briggs, Ryan M.↗
DOE OSTI2022

Optimization of stochastic feature properties in laser powder bed fusion

Process parameter selection in laser powder bed fusion (LPBF) controls the as-printed dimensional tolerances, pore formation, surface quality and microstructure of printed metallic structures. Measuring the stochastic mechanical performance for a wide range of process parameters is cumbersome both in time and cost. As such, in this study, we overcome these hurdles by using high-throughput tensile (HTT) testing of over 250 dogbone samples to examine process-driven performance of strut-like small features, ~1 mm 2 in austenitic stainless steel (316 L). The output mechanical properties, porosity, surface roughness and dimensional accuracy were mapped across the printable range of laser powers and scan speeds using a continuous wave laser LPBF machine. Tradeoffs between ductility and strength are shown across the process space and their implications are discussed. While volumetric energy density deposited onto a substrate to create a melt-pool can be a useful metric for determining bulk properties, it was not found to directly correlate with output small feature performance.

316 L stainless steel↗
DOE OSTI2024

Unveiling mechanisms and onset threshold of humping in high-speed laser welding

The fabrication of fuel cells relies on a rapid laser welding process. However, challenges arise with the occurrence of humping when the welding speed surpasses a critical threshold, which poses difficulties in achieving a smooth surface finish and a consistent weld strength. This study aims to elucidate the humping mechanisms by analyzing the morphology of molten pool and the characteristics of melt flow at varying welding speeds via in situ synchrotron high-speed X-ray imaging and computational fluid dynamics simulations. Our findings indicate that the short keyhole rear wall, the high backward melt velocity, and the prolonged tail of molten pool are the primary factors contributing to the onset of humping. Furthermore, a dimensionless humping index (π h ) was introduced, which successfully captured the onset threshold of humping across different literatures. This index not only provides a quantitative description of the humping formation tendency but also serves as a valuable tool for optimizing the laser welding process.

42 ENGINEERING↗
DOE OSTI2022

Pulse Strengthened and Laser Edge Sealed Vacuum Insulation Glazing

A scalable, low-cost processing strategy for glass strengthening and sealing is proposed to improve the thermal performance of insulating glass units and develop innovative window technologies. In this project, a combination of large area photonic processing, additive manufacturing, and laser encapsulation techniques is reported to realize a vacuum glazing technology to meet the cost, performance, reliability, and throughput demands. A modeling framework for evaluating the mechanical and thermal response was established to verify the structural deformation and thermal conductance. Micro-size glass frits in printing ink and a continuous-wave laser curing were employed to allow the formation of a hermetic bonding layer and led to improvement of glass edge sealing. Various sealing parameters, including laser traveling speed, spot diameter, and laser power were optimized. The water seepage and mechanical strength of the resulting glass-to-glass bonding were examined as well. These results showcase the development of a practical vacuum insulating glazing with several unique features through a combination of photonic processing, laser encapsulation, and additive manufacturing.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

High-throughput, Ultra-fast Laser Sintering of Ceramics and AI Based Prediction on Processing-Microstructure-Property Relationships

We report high-throughput, ultra-fast laser sintering of alumina sample array and characterization of sample units’ microstructure and hardness, as a fast exploration of laser processing parameters, microstructure, and property. These experimental data were used to train machine-learning (ML) models. Accurate ML predictions were demonstrated for the processing-microstructure-property relationship, specifically in (1) prediction of the microstructure of alumina under arbitrary laser power and (2) prediction of the expected microstructure from the desired hardness. An independent neural network was developed and showed that ML-predicted microstructure had less than 10% error from real ones, in terms of projected hardness. To monitor the microstructure during laser sintering, we demonstrated an ML model that can instantaneously predict ceramic’s microstructure at the laser spot, based on the laser spot brightness. The ML model can generate more than 10 predictions per second, and the error in average grain size was less than 5% from the experimental observations.

36 MATERIALS SCIENCE↗
NASA NTRS1978

Laser-enhanced dynamics in molecular rate processes

The present discussion deals with some theoretical aspects associated with the description of molecular rate processes in the presence of intense laser radiation, where the radiation actually interacts with the molecular dynamics. Whereas for weak and even moderately intense radiation, the absorption and stimulated emission of photons by a molecular system can be described by perturbative methods, for intense radiation, perturbation theory is usually not adequate. Limiting the analysis to the gas phase, an attempt is made to describe nonperturbative approaches applicable to the description of such processes (in the presence of intense laser radiation) as electronic energy transfer in molecular (in particular atom-atom) collisions; collision-induced ionization and emission; and unimolecular dissociation.

George, T. F.↗
DOE OSTI2020

The origin and formation of oxygen inclusions in austenitic stainless steels manufactured by laser powder bed fusion

The origins of nano-scale oxide inclusions in 316L austenitic stainless steel (SS) manufactured by laser powder bed fusion (L-PBF) was investigated by quantifying the possible intrusion pathways of oxygen contained in the precursor powder, extraneous oxygen from the process environment during laser processing, and moisture contamination during powder handling and storage. When processing the fresh, as-received powder in a wellcontrolled environment, the oxide inclusions contained in the precursor powder were the primary contributors to the formation of nano-scale oxides in the final additive manufactured (AM) product. These oxide inclusions were found to be enriched with oxygen getter elements like Si and Mn. By controlling the extraneous oxygen level in the process environment, the oxygen level in AM produced parts was found to increase with the extraneous oxygen level. The intrusion pathway of this extra oxygen was found to be dominated by the incorporation of spatter particles into the build during processing. Moisture induced oxidation during powder storage was also found to result in a higher oxide density in the AM produced parts. SS 316L powder free of Si and Mn oxygen getters was processed in a well-controlled environment and resulted in a similar level of oxygen intrusion. Finally, microhardness testing indicated that the oxide volume fraction increase from extraneous oxygen did not influence hardness values. However, a marked decrease in hardness was found for the humidified and Si-Mn free AM processed parts.

36 MATERIALS SCIENCE↗
NASA NTRS1991

Computer Processing Of Tunable-Diode-Laser Spectra

Tunable-diode-laser spectrometer measuring transmission spectrum of gas operates under control of computer, which also processes measurement data. Measurements in three channels processed into spectra. Computer controls current supplied to tunable diode laser, stepping it through small increments of wavelength while processing spectral measurements at each step. Program includes library of routines for general manipulation and plotting of spectra, least-squares fitting of direct-transmission and harmonic-absorption spectra, and deconvolution for determination of laser linewidth and for removal of instrumental broadening of spectral lines.

May, Randy D.↗