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NASA NTRS1990

High temperature acoustic and hybrid microwave/acoustic levitators for materials processing

The physical acoustics group at the Jet Propulsion Laboratory developed a single mode acoustic levitator technique for advanced containerless materials processing. The technique was successfully demonstrated in ground based studies to temperatures of about 1000 C in a uniform temperature furnace environment and to temperatures of about 1500 C using laser beams to locally heat the sample. Researchers are evaluating microwaves as a more efficient means than lasers for locally heating a positioned sample. Recent tests of a prototype single mode hybrid microwave/acoustic levitator successfully demonstrated the feasibility of using microwave power as a heating source. The potential advantages of combining acoustic positioning forces and microwave heating for containerless processing investigations are presented in outline form.

Barmatz, Martin↗

NASA NTRS2008

Carbothermal Processing of Lunar Regolith Using Methane

The processing of lunar regolith for the production of oxygen is a key component of the In-Situ Resource Utilization plans currently being developed by NASA. Among various candidate processes, the modeling of oxygen production by hydrogen reduction, molten salt electrolysis, and carbothermal processing are presently being pursued. In the carbothermal process, a portion of the surface of the regolith in a container is heated by exposure to a heat source such as a laser beam or a concentrated solar heat flux, so that a small zone of molten regolith is established. The molten zone is surrounded by solid regolith particles that are poor conductors of heat. A continuous flow of methane is maintained over the molten regolith zone. Our model is based on a mechanism where methane pyrolyzes when it comes in contact with the surface of the hot molten regolith to form solid carbon and hydrogen gas. Carbon is deposited on the surface of the melt, and hydrogen is released into the gas stream above the melt surface. We assume that the deposited carbon mixes in the molten regolith and reacts with metal oxides in a reduction reaction by which gaseous carbon monoxide is liberated. Carbon monoxide bubbles through the melt and is released into the gas stream. Oxygen is produced subsequently by (catalytically) processing the carbon monoxide downstream. In this paper, we discuss the development of a chemical conversion model of the carbothermal process to predict the rate of production of carbon monoxide.

Balasubramaniam, R.↗

NASA NTRS2009

Carbothermal Processing of Lunar Regolith Using Methane

Balasubramaniam, R.↗

DOE OSTI2022

Sinter formation during directed energy deposition of titanium alloy powders

During directed energy deposition (DED) additive manufacturing, powder agglomeration and sintering can occur outside of the melt pool when using titanium alloy powders. Using in situ synchrotron radiography we investigate the mechanisms by which sintering of Ti6242 powder occurs around the pool, performing a parametric study to determine the influence of laser power and stage traverse speed on sinter build-up. The results reveal that detrimental sinter can be reduced using a high laser power or increased stage traverse speed, although the latter also reduces deposition layer thickness. The mechanism of sinter formation during DED was determined to be in-flight heating of the powder particles in the laser beam. Calculations of particle heating under the processing conditions explored in this study confirm that powder particles can reasonably exceed 700 °C, the threshold for Ti surface oxide dissolution, and thus the powder is prone to sintering if not incorporated into the melt pool. The build-up of sinter powder layer on deposit surfaces led to lack of fusion pores. To mitigate sinter formation and its detrimental effects on DED component quality, it is essential that the powder delivery spot area is smaller than the melt pool, ensuring most powder lands in the melt pool.

36 MATERIALS SCIENCE↗

NASA NTRS2017

Molecular Composition Analysis of Distant Targets

This document is the Final Report for NASA Innovative Advanced Concepts (NIAC) Phase I Grant 15-NIAC16A-0145, titled Molecular Composition Analysis of Distant Targets. The research was focused on developing a system concept for probing the molecular composition of cold solar system targets, such as Asteroids, Comets, Planets and Moons from a distant vantage, for example from a spacecraft that is orbiting the target (Hughes et al., 2015). The orbiting spacecraft is equipped with a high-power laser, which is run by electricity from photovoltaic panels. The laser is directed at a spot on the target. Materials on the surface of the target are heated by the laser beam, and begin to melt and then evaporate, forming a plume of asteroid molecules in front of the heated spot. The heated spot glows, producing blackbody illumination that is visible from the spacecraft, via a path through the evaporated plume. As the blackbody radiation from the heated spot passes through the plume of evaporated material, molecules in the plume absorb radiation in a manner that is specific to the rotational and vibrational characteristics of the specific molecules. A spectrometer aboard the spacecraft is used to observe absorption lines in the blackbody signal. The pattern of absorption can be used to estimate the molecular composition of materials in the plume, which originated on the target. Focusing on a single spot produces a borehole, and shallow subsurface profiling of the targets bulk composition is possible. At the beginning of the Phase I research, the estimated Technology Readiness Level (TRL) of the system was TRL-1. During the Phase I research, an end-to-end theoretical model of the sensor system was developed from first principles. The model includes laser energy and optical propagation, target heating, melting and evaporation of target material, plume density, thermal radiation from the heated spot, molecular cross section of likely asteroid materials, and estimation of the absorption profile at a distant spectrometer. Results obtained by executing simulations based on the model provide compelling evidence that the concept of remote laser evaporative molecular absorption spectroscopy is feasible. In this document, technical details of the model are presented, and results of simulations are described that indicate the utility of the proposed sensor system. Additionally, an asteroid rendezvous mission is analyzed, with a survey of system requirements to accomplish molecular composition analysis of the asteroid. Based on positive theoretical results obtained during Phase I, the estimated TRL of the system is now TRL-2. This document also describes potential future research and experimentation that could push the system to TRL-4 within 2 years. Steps required for construction of a laboratory prototype are described. An experiment to test predictions of the theory is described, based on the laboratory prototype setup.

asteroid↗

NASA NTRS1991

Acoustic Levitator With Furnace And Laser Heating

Acoustic-levitation apparatus incorporates electrical-resistance furnace for uniform heating up to temperature of about 1,000 degrees C. Additional local heating by pair of laser beams raise temperature of sample to more than 1,500 degrees C. High temperature single-mode acoustic levitator generates cylindrical-mode accoustic resonance levitating sample. Levitation chamber enclosed in electrical-resistance furnace. Infrared beams from Nd:YAG laser provide additional local heating of sample. Designed for use in containerless processing of materials in microgravity or in normal Earth gravity.

Barmatz, Martin B.↗

NASA NTRS1995

Measuring Temperature By Laser-Induced-Grating Spectroscopy

Temperature computed from speed of laser-induced counter-propagating acoustic waves. Interference between intersecting pumping laser beams gives rise to spatially periodic heating, which in turn, creates oscillating diffraction grating probed by another laser beam. Oscillations in diffracted probe-laser intensity correspond to oscillations of counter-propagating acoustic waves generated by spatially periodic heating.

VanderWal, Randall L.↗

NASA NTRS1971

The combustion of pure and composite propellants - The expansion and application of laminar flame theory to heterogeneous solid propellants.

Development of a combustion theory based on the laminarized solutions to the energy and flow conservation equations, which is more realistic in recognizing the nature of the heating-rate problem and in obtaining a practical solution to estimating its magnitude. A new experimental approach is used for studying the combustion behavior of pure monopropellants and composite propellants which uses a laser beam to supply additional heat feedback to a burning surface. New experimental data are presented for the laser-induced combustion rate and ignition delay of pure ammonium perchlorate. The pure monopropellant theory is generalized to include such nonadiabatic effects, and the new experimental data are in good agreement with the nonadiabatic theory.-

Hertzberg, M.↗

DOE OSTI2020

Wire-Based Additive Manufacturing of Stainless Steel Components

In this work three different wire-fed additive manufacturing (AM) processes were employed to evaluate differences between laser, arc, and electron beam heat sources used for high-deposition-rate AM on the order of 1 kg/h. Optimum weld and build parameters were developed independently to match the characteristics of each heat source using 308L stainless steel welding wire as the feedstock. Laser-wire AM was made with the lowest energy per unit length of weld and had the best control of the melt pool and surface finish. Wire arc-based AM had an intermediate energy per unit length of weld of approximately 5× that of the laser process, while electron beam wire AM had the highest energy per unit length of weld at approximately 10× that of the laser process. Analysis of the parts that were built included evaluation of mechanical properties and microstructures, and these properties are discussed with respect to the difference in input energy and cooling rates. Results show that all three processes build parts with properties that exceed those of annealed 304L wrought stainless steel. However, significant differences exist between the processes, and the results presented here can be used to help select the best wire-fed process for a given high-deposition-rate application.

36 MATERIALS SCIENCE↗

NASA NTRS1980

Laser-heated thruster

The development of computer codes for the thrust chamber of a rocket of which the propellant gas is heated by a CW laser beam was investigated. The following results are presented: (1) simplified models of laser heated thrusters for approximate parametric studies and performance mapping; (3) computer programs for thrust chamber design; and (3) shock tube experiment to measure absorption coefficients. Two thrust chamber design programs are outlined: (1) for seeded hydrogen, with both low temperature and high temperature seeds, which absorbs the laser radiation continuously, starting at the inlet gas temperature; and (2) for hydrogen seeded with cesium, in which a laser supported combustion wave stands near the gas inlet, and heats the gas up to a temperature at which the gas can absorb the laser energy.

Kemp, N. H.↗

NASA NTRS1992

Axial-Gap Induction Motor For Levitated Specimens

Motor does not obscure view of specimen. Axial-gap induction motor applies torque to rotate electrostatically or electromagnetically levitated specimen of metal. Possible applications include turning specimens for uniform heating under focused laser beams and obtaining indirect measurements of resistivities or of surface tensions in molten specimens.

Sridharan, Govind↗

DOE OSTI2025

Modeling the Interaction of Laser-Produced Proton Beams with Matter

A major goal of this project is to significantly increase our understanding of isochoric heating of matter using laser produced proton beams, and the associated high energy density (HED) and warm dense matter (WDM) regimes generated. This will benefit research fields such as planetary science, fusion energy, plasma physics, and material science. For example, it will enhance our understanding of WDM properties of iron and silica under conditions encountered in planetary interiors and diagnostic components in fusion devices exposed to high fluxes of energetic plasma ions. The project is motivated by recent experiments that irradiated Si targets with proton beams generated by the 20 TW-laser at the SLAC MEC end-station. The HED/WDM states are probed using the 50 fs hard X-rays available in the 3rd harmonic of the LCLS. As part of this project, results from the phase contrast X-ray imaging, which shows the generation of compression waves that produces rear surface spallation, are compared with results from the 3D multi-physics multi- material code, PISALE, that combines Arbitrary Lagrangian-Eulerian (ALE) hydrodynamics with Adaptive Mesh Refinement (AMR). This comparison required modifications to several physics models in the PISALE (Pacific Island Structured-AMR with ALE) code. An important aspect of this project is the continued training of graduate students in HED physics and in conducting complex multiphysics simulations.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2020

Transport of kJ-laser-driven relativistic electron beams in cold and shock-heated vitreous carbon and diamond

We report experimental results on relativistic electron beam (REB) transport in a set of cold and shock-heated carbon samples using the high-intensity kilojoule-class OMEGA EP laser. The REB energy distribution and transport were diagnosed using an electron spectrometer and x-ray fluorescence measurements from aCu tracer buried at the rear side of the samples. The measured rear REB density shows brighter and narrower signals when the targets were shock-heated. Hybrid PIC simulations using advanced resistivity models in the target warm-dense-matter (WDM) conditions confirm this observation. We show that the resistivity response of the media, which governs the self generated resistive fields, is of paramount importance to understand and correctly predict the REB transport.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS2006

Optically Driven Deformable Mirrors

Optically driven deformable mirrors may eventually supplant electrically driven deformable mirrors in some adaptive-optics and active-optics applications. Traditionally, the mirror facets in electrically driven deformable mirrors are actuated, variously, by means of piezoelectric, electrostrictive, microelectromechanical, liquid-crystal, or thermal devices. At least one such device must be dedicated to each facet, and there must be at least one wire carrying a control or drive signal to the device. If a deformable mirror comprises many (e.g., thousands) of facets, then wiring becomes a major problem for design, and the problem is compounded in cases of piezoelectric or other actuators for which high drive voltages are required. In contrast, in optically driven mirrors, the wiring problem is eliminated. The basic principle of actuation of an optically driven deformable mirror is to use a laser beam to actuate a material. For example, a laser beam can be used to heat a material to make the material thermally expand to displace a mirror facet. In an experiment to demonstrate this principle, the actuator was a Golay cell having a diameter of approximately equal to 6 mm and a length of approximately equal to 10 mm. The beam from a laser diode was aimed at an absorber in the cell, thereby heating the gas in the cell. A mirror mounted on a 12.5-micron-thick polyethylene terephthalate diaphragm at one end of the cell became displaced as the gas expanded against the diaphragm. In one representative pair of experiments at a laser beam power of 0.23 W, the beam was mechanically chopped at frequencies of 1 and 5 Hz. The mirror exhibited corresponding oscillating displacements having amplitudes of 373 and 83 micron, respectively

Hemmati, Hamid↗

NASA NTRS1975

Dense plasma focus production in a hypocycloidal pinch

A type of high-power pinch apparatus consisting of disk electrodes was developed, and diagnostic measurements to study its mechanism of dense plasma production were made. The collapse fronts of the current sheets are well organized, and dense plasma focuses are produced on the axis with radial stability in excess of 5 microns. A plasma density greater than 10 to the 18th power/cubic cm was determined with Stark broadening and CO2 laser absorption. A plasma temperature of approximately 1 keV was measured with differential transmission of soft X-rays through thin foils. Essentially complete absorption of a high-energy CO2 laser beam was observed. The advantages of this apparatus over the coaxial plasma focus are in (1) the plasma volume, (2) the stability, (3) the containment time, (4) the easy access to additional heating by laser or electron beams, and (5) the possibility of scaling up to a multiple array for high-power operation.

Lee, J. H.↗

NASA NTRS1990

Beam Stop For High-Power Lasers

Graphite/aluminum plate absorbs most of light. Beam stop fits on standard optical mounting fixture. Graphite plate thick enough to absorb incident laser beam but thin enough to transfer heat quickly to heat sink. Device used for variety of blocking purposes. For example, blocks laser beam after it passes through experimental setup, or at each stage of setup so stages checked and tested in sequence. Negligible reflectance of device is valuable safety feature, protecting both users and equipment from reflections.

Mcdermid, Iain S.↗

NASA NTRS1990

NASA-sponsored containerless processing experiments

An outline is presented of containerless processing and facilities at Intersonics which is sponsored by NASA. There are electromagnetic, acoustic, and aerodynamic levitation facilities. There are also laser beam and arc lamp heating systems along with state of the art noncontact temperature and optical property measurement facilities. Nonintrusive diagnostic techniques with Laser Induced Fluorescence and mass spectrometer are also available. Controlled atmosphere processing, gas quenching, and proven microgravity processing technology is part of the Intersonics capabilities.

Hofmeister, William H.↗

DOE OSTI2023

Self-consistent integrated modeling of combined hybrid discharge-laser produced plasma devices for extreme ultraviolet metrology

Discharge- and laser-produced plasma (DLPP) devices are being used as light sources for extreme ultraviolet (EUV) generation. A key challenge for both, DPP and LPP, is achieving sufficient brightness to support the throughput requirements of nanometrology tools. To simulate the environment of a hybrid DLPP device and optimize the EUV output, we have developed an integrated HEIGHTS-DLPP computer simulation package. The package integrates simulation of two evolving plasmas (DPP and LPP) and includes modeling of a set of integrated self-consistent processes: external power source and plasma energy balance, plasma resistive magnetohydrodynamics, plasma heat conduction, detailed radiation transport (RT), and laser absorption and refraction. We simulated and optimized DLPP devices using Xe gas as a target material. We synchronized the external circuit parameters, chamber gas parameters, and laser beam temporal and spatial profiles to achieve maximum EUV output. The full 3D Monte Carlo scheme was integrated for detailed RT and EUV output calculations in Xe using more than 3600 spectral groups. The modeling results are in good agreement with Julich Forschungszentrum experimental data. Theoretical models, developed and integrated into the HEIGHTS package, showed wide capabilities and flexibility. In conclusion, the models and package can be used for optimization of the experimental parameters and settings, investigation of DLPP devices with complex design, analyzing the impact of integrated spatial effects and working timeline arrangement on the final EUV output, and EUV source size, shape, and angular distribution.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗