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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 325 records · Page 18
All sourcesNASA NTRSDOE OSTI
NASA NTRS1983

Laser assisted deposition

Applications of laser-based processing techniques to solar cell metallization are discussed. Laser-assisted thermal or photolytic maskless deposition from organometallic vapors or solutions may provide a viable alternative to photovoltaic metallization systems currently in use. High power, defocused excimer lasers may be used in conjunction with masks as an alternative to direct laser writing to provide higher throughput. Repeated pulsing with excimer lasers may eliminate the need for secondary plating techniques for metal film buildup. A comparison between the thermal and photochemical deposition processes is made.

Dutta, S.↗
NASA NTRS1979

Molecular collision processes in the presence of picosecond laser pulses

Radiative transitions in molecular collision processes taking place in the presence of picosecond pulses are studied within a semiclassical formalism. An expression for adiabatic potential surfaces in the electronic-field representation is obtained, which directly leads to the evaluation of transition probabilities. Calculations with a Landau-Zener-type model indicate that picosecond pulses can be much more effective in inducing transitions than a single long pulse of the same intensity and the same total energy, if the intensity is sufficiently high that the perturbation treatment is not valid.

Lee, H. W.↗
DOE OSTI2025

Suppressing Ordering in Equiatomic Fe-Co via Laser Powder Bed Fusion

Neutron and electron diffraction was employed to evaluate the effectiveness of thermal management strategies in suppressing the formation of the equilibrium-ordered B2 (CsCl) phase in equiatomic binary Fe-Co specimens fabricated by laser powder bed fusion additive manufacturing. Specimens with a tensile dogbone geometry were fabricated using various combinations of process parameters (laser power and raster speed) and thermal management strategies (no support struts, struts only in the top gauge section, and struts throughout the gauge section). Diffraction results demonstrate that the rapid solidification during PBF-L effectively minimized B2 formation, with laser power and effective scan velocity having no significant impact on the degree of ordering. Furthermore, the inclusion of support struts in the top grip region had no perceivable impact on ordering, whereas specimens with support struts in the gauge region exhibited no detectable ordering. Results are discussed in the context of thermal finite element analysis predictions.

Laser Material Processing↗
NASA NTRS1978

Measurements of kinetic processes in a self-sustained discharge XeF laser

Measurements are presented for processes occurring in XeF self-sustained discharges including fluorescence, gain, and absorption at different wavelengths as a function of F2, Xe, and He partial pressures. Time-correlated oscillograms are given for the laser discharge current, metastable XeF small-signal gain at 351.1 nm, transient absorptions at 333.6 and 363.8 nm, metastable-XeF B-state sidelight emission at about 350 nm, metastable-F emission at 634.8 nm, and metastable-F emission at 731.1 nm. It is found that He atoms are necessary for the production of metastable-XeF in its lower vibrational levels and that radiative processes and He quenching are the primary mechanisms for metastable-XeF decay. For small-signal gains of as low as about 8%/cm, the transient absorption at the laser wavelength may be as large as about 1-2%/cm.

Gower, M. C.↗
DOE OSTI2024

Mechanical and thermal behavior of additively manufactured Invar 36 using a laser hot wire hybrid DED process

Invar 36 alloy is a material of high interest in the composite tooling sector due to its low coefficient of thermal expansion. Current production of Invar 36 tooling using traditional manufacturing such as casting and forging is associated with long lead times due to a multitude of factors such as labor and component shortages, high material costs, foreign competition, and supply chain issues. An attractive alternate process is the use of an integrated 5-axis CNC hybrid Laser Hot Wire Deposition System (LHWD) for manufacturing invar molds. Here, the hybrid process provides a combination of the additive and subtractive technologies resulting in a synergistic platform for producing and repairing structures and molds. The main novelty and goal of this work is to study the properties of Invar deposited by a LHWD and to provide guidelines for the manufacture of parts using this process. In this study, the thermal expansion behavior of the manufactured specimens has been analyzed and related to its printing parameters and direction. Multiple specimens were extracted for mechanical, dilatometry and metallographic testing. A thermal IR recording of the printing process was also carried out to observe the thermal history of the produced parts to establish thermal influence on performance-property-processing relationship. The results of these tests show the advantage of LHWD technology for the manufacture of Invar alloy parts, as it presents similar thermal expansion behavior as those commercially available with minimal presence of precipitates and no macrostructural failures such as pores, cracks and lacks of fusion.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Photoluminescence and Raman spectroscopy of wide bandgap semiconductors damaged by deep-UV laser irradiation

The effects of a pulsed, focused, deep-UV (4.66 eV) laser on wide and ultra-wide bandgap semiconductors were investigated with photoluminescence (PL) and Raman spectroscopy. Three semiconductor single crystals were studied: silicon carbide (6H-SiC), gallium nitride (GaN), and gallium oxide (β-Ga 2 O 3 ). Atomic emission lines from neutral Ga or Si were observed during the laser-damage process. For all three semiconductors, PL mapping (3.49 eV laser excitation) of the damaged material revealed visible emission bands in the 2.6–2.8 eV range, attributed to point defects. Raman spectra (2.33 eV excitation) showed a reduction in the Raman peak intensities in the damaged region, along with weak PL bands around 1.9–2.1 eV.

36 MATERIALS SCIENCE↗
NASA NTRS2010

First Demonstration on Direct Laser Fabrication of Lunar Regolith Parts

Establishment of a lunar or Martian outpost necessitates the development of methods to utilize in situ mineral resources for various construction and resource extraction applications. Fabrication technologies are critical for habitat structure development, as well as repair and replacement of tools and parts at the outpost. Herein we report the direct fabrication of lunar regolith simulant parts, in freeform environment, using lasers. We show that raw lunar regolith can be processed at laser energy levels as a low as 2.12 J mm-2 resulting in nanocrystalline and/or amorphous microstructures. Potential applications of laser based fabrication technologies to make useful regolith parts for various applications including load bearing composite structures, radiation shielding, and solar cell substrates is described.

Balla, Vamsi Krishna↗
NASA NTRS2012

Finite Element Models for Electron Beam Freeform Fabrication Process

Electron beam freeform fabrication (EBF3) is a member of an emerging class of direct manufacturing processes known as solid freeform fabrication (SFF); another member of the class is the laser deposition process. Successful application of the EBF3 process requires precise control of a number of process parameters such as the EB power, speed, and metal feed rate in order to ensure thermal management; good fusion between the substrate and the first layer and between successive layers; minimize part distortion and residual stresses; and control the microstructure of the finished product. This is the only effort thus far that has addressed computer simulation of the EBF3 process. The models developed in this effort can assist in reducing the number of trials in the laboratory or on the shop floor while making high-quality parts. With some modifications, their use can be further extended to the simulation of laser, TIG (tungsten inert gas), and other deposition processes. A solid mechanics-based finite element code, ABAQUS, was chosen as the primary engine in developing these models whereas a computational fluid dynamics (CFD) code, Fluent, was used in a support role. Several innovative concepts were developed, some of which are highlighted below. These concepts were implemented in a number of new computer models either in the form of stand-alone programs or as user subroutines for ABAQUS and Fluent codes. A database of thermo-physical, mechanical, fluid, and metallurgical properties of stainless steel 304 was developed. Computing models for Gaussian and raster modes of the electron beam heat input were developed. Also, new schemes were devised to account for the heat sink effect during the deposition process. These innovations, and others, lead to improved models for thermal management and prediction of transient/residual stresses and distortions. Two approaches for the prediction of microstructure were pursued. The first was an empirical approach involving the computation of thermal gradient, solidification rate, and velocity (G,R,V) coupled with the use of a solidification map that should be known a priori. The second approach relies completely on computer simulation. For this purpose a criterion for the prediction of morphology was proposed, which was combined with three alternative models for the prediction of microstructure; one based on solidification kinetics, the second on phase diagram, and the third on differential scanning calorimetry data. The last was found to be the simplest and the most versatile; it can be used with multicomponent alloys and rapid solidification without any additional difficulty. For the purpose of (limited) experimental validation, finite element models developed in this effort were applied to three different shapes made of stainless steel 304 material, designed expressly for this effort with an increasing level of complexity. These finite element models require large computation time, especially when applied to deposits with multiple adjacent beads and layers. This problem can be overcome, to some extent, by the use of fast, multi-core computers. Also, due to their numerical nature coupled with the fact that solid mechanics- based models are being used to represent the material behavior in liquid and vapor phases as well, the models have some inherent approximations that become more pronounced when dealing with multi-bead and multi-layer deposits.

Chandra, Umesh↗
DOE OSTI2024

A Microchannel Heat Exchanger Produced From a Metal Matrix Composite by Hybrid Laser Powder Bed Fusion and Inkjet Printing

Abstract This paper explores the production of an oxide dispersion strengthened (ODS) 304L stainless steel microchannel heat exchanger (HX) using a hybrid additive manufacturing process of laser powder bed fusion and inkjet printing. The study investigates the capabilities and economics of the hybrid inkjet-laser powder bed fusion (LPBF) process and evaluates the dimensional accuracy, functionality, and mechanical properties of the resulting ODS alloy. The effectiveness and pressure drop of the ODS heat exchangers produced by the hybrid LPBF tool are also determined. Results show that the inkjet-doped samples have a lower mean channel height with higher standard deviation than samples produced by LPBF alone. This is attributed to greater absorption of laser energy for the powder coated with the oxide precursor. The economic analysis shows that the hybrid process has a potential for reducing the unit cost of the heat exchanger based on cost modeling assumptions.

Engineering↗
NASA NTRSDate not supplied

Femtosecond Laser-Structured Transparent Anti-Fog Polycarbonate for Visor Applications

AlchLight has developed transparent anti-fog superhydrophobic polycarbonates for spacesuit helmets using femtosecond pulsed laser surface patterning technology. In contrast to conventional complex chemical coating processes, our laser patterning permanently alters the intrinsic wetting property of polycarbonate with little change to its transparency. The processing procedure is studied and optimized to produce the ideal superhydrophobic property and transparency. We were able to obtain a high contact angle (>150°), small sliding angle (<10°), and high transmission (>70%) over the visible wavelengths for polycarbonates. The anti-fog effect was also investigated. This technology will have a range of applications in spacesuit, automotive, medical, energy, and sports industries.

Spacesuit↗
DOE OSTI2020

Types of spatter and their features and formation mechanisms in laser powder bed fusion additive manufacturing process

Spatter causes defect formation, powder redistribution and contamination in laser powder bed fusion (LPBF) additive manufacturing process. It is critical to distinguish different types of spatter and understand their features and formation mechanisms. This work reveals the features and formation mechanisms of five unique types of spatter during the LPBF process by in-situ high-speed, high-energy x-ray imaging. Spatters observed during LPBF testing are quantified by their speed, size, and direction. Distinct quantifiable characteristics for each type of spatter are identified. Finally, effects of the laser power, scan speed, and ambient pressure on spatter formation and features are unraveled. A spatter formation map for AlSi10Mg alloy is constructed.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Creation of Multi-Principal Element Alloy NiCoCr Nanostructures via Nanosecond Laser-Induced Dewetting

The multi-principal element alloy nanoparticles (MPEA NPs), a new class of nanomaterials, present a highly rewarding opportunity to explore new or vastly different functional properties than the traditional mono/bi/multimetallic nanostructures due to their unique characteristics of atomic-level homogeneous mixing of constituent elements in the nanoconfinements. Here, in this paper, the successful creation of NiCoCr nanoparticles, a well-known MPEA system is reported, using ultrafast nanosecond laser-induced dewetting of alloy thin films. Nanoparticle formation occurs by spontaneously breaking the energetically unstable thin films in a melt state under laser-induced hydrodynamic instability and subsequently accumulating in a droplet shape via surface energy minimization. While NiCoCr alloy shows a stark contrast in physical properties compared to individual metallic constituents, i.e., Ni, Co, and Cr, yet the transient nature of the laser-driven process facilitates a homogeneous distribution of the constituents (Ni, Co, and Cr) in the nanoparticles. Using high-resolution chemical analysis and scanning nanodiffraction, the environmental stability and grain arrangement in the nanoparticles are further investigated. Thermal transport simulations reveal that the ultrashort (≈100 ns) melt-state lifetime of NiCoCr during the dewetting event helps retain the constituent elements in a single-phase solid solution with homogenous distribution and opens the pathway to create the unique MPEA nanoparticles with laser-induced dewetting process.

36 MATERIALS SCIENCE↗