Engineering Papers⌕ Search

SEARCH · Engineering Papers

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 289 records · Page 16
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Ion microscopy with evolutionary-algorithm-based autofocusing

Abstract Ion microscopy is an established technique for laser focus diagnostics and the accurate, intensity-resolved measurement of laser ionization processes. In the present feasibility study, we discuss a new ion microscope design, which improves its resolution across a large range of magnifications and simplifies its operation. Instead of the common two einzel lens configuration, which is usually optimized for a fixed magnification, we propose a generic design consisting of an array of equally spaced ring electrodes, whose individually adjustable voltages are controlled by an evolutionary algorithm. In this way, we can realize aberration minimized magnifications between 25 and 100. Moreover, the algorithm can adjust the voltage settings under changing experimental conditions and facilitates autofocusing for user-defined magnification.

Haniel, Franz E.↗
DOE OSTI2025

Laser-Induced Spectral Diffusion of T Centers in Silicon Nanophotonic Devices

Color centers in silicon are emerging as spin-photon interfaces operating at telecommunication wavelengths. The nanophotonic device integration of silicon color centers via ion implantation leads to significant optical-linewidth broadening, which makes indistinguishable photon generation challenging. Here, we study the optical spectral diffusion of T centers in a silicon photonic crystal cavity. We investigate the linewidth-broadening timescales and origins by measuring the temporal correlations of the resonance frequency under different conditions. Spectral hole-burning measurements reveal no spectral broadening at short timescales from 102 ns to 725 ns. We probe broadening at longer timescales using a check pulse to herald the T-center frequency and a probe pulse to measure the frequency after a wait time. The optical resonance frequency is stable up to 3 ms in the dark. Laser pulses below the silicon band gap applied during the wait time lead to linewidth broadening. Our observations establish laser-induced processes as the dominant spectral-diffusion mechanism for T centers in devices and inform materials and feedback strategies for indistinguishable photon generation.

Zhang, Xueyue↗
DOE OSTI2022

Electrophoretic Deposition of Platinum Nanoparticles using Ethanol-Water Mixtures Significantly Reduces Neural Electrode Impedance

We report platinum electrodes are critical components in many biomedical devices, an important example being implantable neural stimulation or recording electrodes. However, upon implantation, scar tissue forms around the electrode surface, causing unwanted deterioration of the electrical contact. We demonstrate that sub-monolayer coatings of platinum nanoparticles (PtNPs) applied to 3D neural electrodes by electrophoretic deposition (EPD) can enhance the electrode's active surface area and significantly lower its impedance. In this work we use ethanol-water mixtures as the EPD solvent, in contrast to our previous studies carried out in water. We show that EPD coating in 30 vol.% ethanol improves the device's electrochemical performance. Computational mesoscale multiparticle simulations were for the first time applied to PtNP-on-Pt EPD, revealing correlations between ethanol concentration, electrochemical properties, and coating homogeneity. Thereto, this optimum ethanol concentration (30 vol.%) balances two opposing trends: (i) the addition of ethanol reduces water splitting and gas bubble formation, which benefits surface coverage, and (ii) increased viscosity and reduced permittivity occur at high ethanol concentrations, which impair the coating quality and favoring clustering. A seven-fold increase in active surface area and significantly reduced in vitro impedance of the nano-modified neural stimulation electrode surfaces highlight the influence of ethanol-water mixtures in PtNP EPD.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Confidentiality-preserving machine learning algorithms for soft-failure detection in optical communication networks

Automated fault management is at the forefront of next-generation optical communication networks. The increase in complexity of modern networks has triggered the need for programmable and software-driven architectures to support the operation of agile and self-managed systems. In these scenarios, the European Telecommunications Standards Institute zero-touch network and service management approach is imperative. The need for machine learning algorithms to process the large volume of telemetry data brings safety concerns as distributed cloud-computing solutions become the preferred approach for deploying reliable communication network automation. This paper’s contribution is twofold. First, we propose a simple yet effective method to guarantee the confidentiality of the telemetry data based on feature scrambling. The method allows the operation of third-party computational services without direct access to the full content of the collected data. Additionally, the effectiveness of four unsupervised machine learning algorithms for soft-failure detection is evaluated when applied to the scrambled telemetry data. The methods are based on factor analysis, principal component analysis, nonlinear principal component analysis, and singular value decomposition. Most dimensionality reduction algorithms have the common property that they can maintain similar levels of fault classification performance while hiding the data structure from unauthorized access. Evaluations of the proposed algorithms demonstrate this capability.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2021

Simulating Dopant Diffusion in a Detalied Porous Structure

The National Ignition Facility (NIF) at Lawrence Livermore National Laboratory (LLNL) uses highpowered lasers to explore cutting edge fusion technology. Specialized optics, known as fiber lasers, generate and amplify the NIF’s high-powered lasers that facilitate fusion experiments. Fiber lasers are glass fibers that are doped with heavy elements to stimulate light emission. The fiber laser doping processing uses a predeposited layer of porous silica nanoparticles on the surface of the glass to absorb a dopant rich salt solution. Our project simulated the diffusion of dopants into porous silica with prescribed colloidal stacking geometries using COMSOL Multiphysics. With these simulations we identified the porosity and tortuosity of the porous nanoparticle structures as the primary parameters that will dictate how the dopants will diffusive into the porous surface of the glass. Porosity and Tortuosity are geometric parameters that can easily be input into more detailed simulations to estimate an effective diffusivity within the porous layer. Future work should account for surface reactions to accurately simulate the full-scale diffusion of the solution doping process.

36 MATERIALS SCIENCE↗
DOE OSTI2024

CHARACTERIZATION OF FATIGUE BEHAVIORS OF NOTCHED 316L DED AM SPECIMENS

ASME Codification of Additive Manufacturing • Integration of AM into ASME Codes and Standards • The ASME goal is to have AM requirements in ASME Code Cases preceding the 2025 Edition. • The ASME Special Committee on AM has drafted criteria for two Code Cases for Additive Manufacturing. • AM Construction of Pressure Equipment using the Direct Energy Deposition Process with Wire Feedstock. • Includes Gas Metal Arc Welding. • Time-independent material properties. • Status - Criteria endorsed by AM Committee. • AM Construction of Pressure Equipment using the Powder Bed Fusion AM Process. • Includes Laser and Electron Beam Energy Sources. • Austenitic and Nonferrous materials. • Time-independent material properties. • Status – Approval ballot circulating to the AM Committee.

Krentz, Timothy M.↗
DOE OSTI2026

Gaseous Hydrogen Embrittlement of L-PBF Ni-Based Superalloys for Service in Natural Gas Turbines

Efforts to improve efficiency of industrial gas turbine engines have focused on increasing operating temperatures by use of fuel-flexible gas blends. Ni-based superalloys are susceptible to hydrogen embrittlement (HE), leading to potential risk of premature component failure. Certain turbine components exposed to hydrogen-rich environments are manufactured from additive processes like laser powder bed fusion (L-PBF). The HE susceptibility was evaluated for three Ni-based superalloys: solid solution strengthened Alloy 625, γ’/γ’’-precipitation strengthened Alloy 718, and γ’-precipitation strengthened Haynes® 282®. L-PBF samples were pre-charged under medium and high pressure gaseous hydrogen before tensile testing at temperatures up to 260 °C using a fast strain rate. Selected samples were subjected to a service conditioning heat treatment prior to hydrogen charging to evaluate the change in susceptibility after prolonged service. The susceptibility to HE and HE mechanisms of these three alloys is compared.

additive manufacturing↗
DOE OSTI2025

Microstructural evaluation of thin-wall sections of 316L stainless steel produced by laser powder-bed fusion processing

The synthesis of thin wall sections that are only 0.4 mm thick is achieved with LPBF AM. Sample preparation is optimized using metallographic polishing to produce samples with only 0.3 um rms roughness for scanning electron microanalysis with EBSD and EDS. A fully austenitic 316L phase is found without evidence of secondary phases. Unlike some AM products that can readily evidence composition segregation due to solute rejection as attributable to temperature gradients within the solidification

Jankowski, Alan F. [Sandia National Laboratories (↗
DOE OSTI2020

Additively Manufactured Interdigital Filters for Ultra- Wideband Radar

Abstract— In this paper, we present the development of ultrawideband (UWB) inter-digital cavity filters manufactured with an additive technique. We employed a selective laser melting process with stainless steel via a “flipping and fixturing” approach to achieve dimensional accuracy and frequency selectivity (no postfabrication tuning) comparable to that of conventional micromachining. The filters operate at a center frequency of 3.75 GHz and 6 GHz, respectively, with an instantaneous bandwidth of 2 GHz. This paper presents design and fabrication details, a discussion of measured characteristics for both filters, and a performance comparison with respect to subtractively manufactured parts.

Keywords— Interdigital filters, UWB radar, additiv↗
DOE OSTI2024

Using double pulse laser ablation in air to enhance the strength of laser-driven shocks

In the process of multi-pulse laser ablation, inter-pulse delay time, Δ t , is known to be an important parameter for maximizing ablation efficiency as well as impulse imparted to the target. In this work, using photon Doppler velocimetry, we show that for single pairs of colinear pulses (1064 nm, 8 ns, ∼ 60 J cm -2 per pulse) in air, the peak free surface velocity of the back surface of an aluminum target (125 µm thick) is increased, by a factor of nearly 3, when Δ t = 10 microseconds, compared with both pulses arriving simultaneously (Δ t = 0). Fast imaging of the ablation process suggests this enhancement is due to rarefaction of the contiguous air in the passage of the leading shock produced by ablation, which then in turn allows a larger fraction of the energy of the second pulse to reach the target surface. This interpretation is strengthened by additional experiments in which the two pulses do not overlap on the target surface, but the shock strength is nevertheless enhanced. Given a fixed energy budget this work suggests a prescription for maximizing laser-driven shock strength by judicious choice of inter-pulse delay.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2025

THz Radiation Generation to Enable Internal Magnetic Field Measurement of Burning Plasmas (Final Scientific Report)

A one-year experimental program was performed using the Multi-TeraWatt (MTW) laser at the Laboratory for Laser Energetics (LLE) to investigate the efficiency and physical process of laser-driven—wire THz generation. This process was evaluated as a potential high-repetition-rate source of powerful THz pulses for use in THz pulsed polarimetry of a moderate-density magnetic-confinement fusion concept developed by TAE. The goal was to develop a source for short pulses in the THz regime (150 μm wavelength) containing 10’s of mJ. The campaign tested the impact of Cu wire diameter (25, 75, 160 μm), length (250 – 750 μm), and laser irradiation orientation on THz production efficiency in comparison to 20-μm thick Cu foils. Of these targets, the 160 µm diameter, 750 µm long wires with sharpened tips and irradiated at the base were found to produce the highest energy and shortest wavelength THz pulses, exceeding 2.5 Joule/sr and meeting the requirements for the polarimetry diagnostic. The brightest THz signal was radiated in the direction of the sharpened wire tip. A combination of two models – a traveling wave antenna combined with coherent transition radiation – describes the emission pattern, pulse energy, and spectrum observed in the experiments.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

Evolution of AISI 304L stainless steel part properties due to powder recycling in laser powder-bed fusion

Selective laser melting (SLM) is a powder-bed fusion process in Additive Manufacturing (AM) that uses a laser beam to selectively fuse layers of powder into near net-shape components with little porosity. However, inconsistencies in the part properties due to the presence of defects in as-built components has hindered the widespread adoption of SLM for industrial applications forcing researchers to study the sources of variation for quality control purposes. A critical area suspected of creating variation in the part properties is the feedstock, where batch-to-batch differences as well as changes in the powder properties with reuse have the potential to affect performance. During processing, laser spatter and condensate eject from the melt pool and deposit into the powder-bed surrounding the parts. These particulates, more commonly known as ejecta, differ morphologically and chemically from the virgin powder compromising its reusability. In this study, 304L stainless steel powder was recycled for a total of 5 times through a systematic approach aimed at accelerating powder degradation to reveal the influence on both the tensile and impact toughness properties. Through analysis of variance (ANOVA), it was found that tensile properties did not change with reuse, while the impact toughness showed a steady decline illustrating the differences in static and dynamic part properties due to powder recycling.

36 MATERIALS SCIENCE↗
DOE OSTI2023

A Co-Registered In-Situ and Ex-Situ Tensile Properties Dataset from a Laser Powder Bed Fusion Additive Manufacturing Process (Peregrine v2023-11)

This release contains a co-registered in-situ and ex-situ Peregrine dataset from five Concept Laser M2 Laser Powder Bed Fusion (L-PBF) stainless steel 316L builds containing 6,299 SS-J3 individually tracked tensile coupons. These data were collected at the Manufacturing Demonstration Facility (MDF) located at Oak Ridge National Laboratory (ORNL). The dataset includes layer-wise visible-light in-situ imaging data, the laser scan paths and parameters, in-situ temporal sensor data, room-temperature static tensile test results, and the target part geometries. Additionally, anomaly detections produced by a modified Dynamic Segmentation Convolutional Neural Network (DSCNN) are provided.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Effect of processing parameters and build orientation on microstructure and performance of AISI stainless steel 304L made with selective laser melting under different strain rates

Selective laser melting (SLM) process brings diverse potentials on geometry flexibility; therefore, it is more and more widespread to be employed in fabrication metal alloys served for industries. Nonetheless, a material characterization study is desired to carry on for better understanding the correlation among process, structure, microstructure, and performance. In the current study, the SLM fabricated AISI stainless steel 304L was fabricated with different process parameters and built orientations (horizontal, inclined, and vertical. The tensile behavior was evaluated under different strain rates (0.0001 /s, 0.001 /s, 0.01 /s, and 0.1 /s) and compared to the commercial cold-rolled and annealed counterpart. Grain structures, tensile strength, elongation-to-failure, strain rate sensitivity, work hardening, and fractographic analysis were evaluated in terms of the effect of energy density, build orientation, and strain rate. The output indicates the tensile strength increases with increasing strain rates. On the contrary, the elongation-to-failure shows a decreasing trend with strain rates. Tensile properties of specimens built in the horizontal and inclined orientations are more sensitive to strain rates due to the smaller dimension of grain structures. Tensile anisotropy depends on the energy input, where a high energy density could yield a strong build orientation-dependent anisotropy. Hall-Petch relationship is validated to explain the mechanical anisotropy in different built orientations for SLM alloys. The strain hardening exponent and work hardening rate are demonstrated to be positively correlated, and they increase with smaller grain sizes. The fine dimple features indicate the ductile fracture mode regardless of strain rates. The size of the ductile dimples seems to depend on the strain rates and build orientations.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Birefringent Glass‐Engraved Quasi‐Linear Nanograting Metasurface Based on Self‐Organizing Process for Large Aperture High Power Laser Applications

All-glass metasurface “nanograting” structures that exhibit birefringence in the formed layer are reported. The key enabler of this work is ion beam processing at an angle sufficiently off-normal incidence, inducing self-assembly of a deposited metal layer into quasi-linear metallic features that can function as an etching mask. As a result, a fused silica metasurface, monolithic to the underlying substrate, is demonstrated at 375 nm wavelength to exhibit a phase delay angle of 30° between the principal axes. The capability of an angled etch mask replenishment process is also demonstrated for achieving deeper etch depth and for increasing the grating period, another first – to the best of the knowledge. This is the first display of a technology capable of fabricating glass-engraved near-linear grating structure with a feature-to-feature period as small as 118.6 nm. Furthermore, this technology has the potential to generate grating-like structures with periods as small as 12.4 nm, as demonstrated here with reactive ion beam processing assisted mask assembly. Furthermore, these structures are shown to have reflectivity < 0.4% across the wavelength band 350 nm – 1000 nm. Such a technology can enable laser-durable grating structures for the deep-UV and even down to soft X-ray wavelengths.

Ray, Nathan J. [Lawrence Livermore National Labora↗
DOE OSTI2023

A Co-Registered In-Situ and Ex-Situ Dataset from a Laser Powder Bed Fusion Additive Manufacturing Process (Peregrine v2023-10)

This release contains a co-registered in-situ and ex-situ Peregrine dataset from a single Concept Laser M2 Laser Powder Bed Fusion (L-PBF) stainless steel 316L build. These data were collected at the Manufacturing Demonstration Facility (MDF) located at Oak Ridge National Laboratory (ORNL). The dataset includes layer-wise visible-light in-situ imaging data, the laser scan paths and parameters, in-situ temporal sensor data, X-Ray Computed Tomography (X-CT) scans, pycnometry and tensile test results, etched micrographs from selected locations, and the target part geometries. Additionally, anomaly detections produced by a modified Dynamic Segmentation Convolutional Neural Network (DSCNN) are provided.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Laser-initiated p – 11 B fusion reactions in petawatt high-repetition-rate laser facilities

Driving of the nuclear fusion reaction p + 11 B → 3α + 8.7 MeV under laboratory conditions by interaction between high-power laser pulses and matter has become a popular field of research, owing to its numerous potential applications: as an alternative to deuterium–tritium for fusion energy production, astrophysics studies, and alpha-particle generation for medical treatment. One possible scheme for laser-driven p– 11 B reactions is to direct a beam of laser-accelerated protons onto a boron (B) sample (the so-called “pitcher-catcher” scheme). This technique has been successfully implemented on large high-energy lasers, yielding hundreds of joules per shot at low repetition. We present here a complementary approach, exploiting the high repetition rate of the VEGA III petawatt laser at CLPU (Spain), aiming at accumulating results from many interactions at much lower energy, to provide better control of the parameters and the statistics of the measurements. Despite a moderate energy per pulse, our experiment allowed exploration of the laser-driven fusion process with tens (up to hundreds) of laser shots. The experiment provided a clear signature of the reactions involved and of the fusion products, accumulated over many shots, leading to an improved optimization of the diagnostics for experimental campaigns of this type. In this paper, we discuss the effectiveness of laser-driven p– 11 B fusion in the pitcher–catcher scheme, at a high repetition rate, addressing the challenges of this experimental scheme and highlighting its critical aspects. Our proposed methodology allows evaluation of the performance of this scheme for laser-driven alpha particle production and can be adapted to high-repetition-rate laser facilities with higher energy and intensity.

Alpha particles↗