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At least 415 records · Page 23

A laser communication experiment utilizing the ACT satellite and an airborne laser transceiver

The launch of a laser communication transmitter package into geosynchronous Earth orbit onboard the Advanced Communications Technology Satellite (ACTS) will present an excellent opportunity for the experimental reception of laser communication signals transmitted from a space orbit. The ACTS laser package includes both a heterodyne transmitter (Lincoln Labs design) and a direct detection transmitter (Goddard Space Flight Center design) with both sharing some common optical components. NASA Lewis Research Center's Space Electronics Division is planning to perform a space communication experiment utilizing the GSFC direct detection laser transceiver. The laser receiver will be installed within an aircraft provided with a glass port for the reception of the signal. This paper describes the experiment and the approach to performing such an experiment. Described are the constraints placed on the NASA Lewis experiment by the performance parameters of the laser transmitter and by the ACTS spacecraft operations. The conceptual design of the receiving terminal is given; also included is the anticipated capability of the detector.

Provencher, Charles E., Jr.↗

Overview and future direction for blackbody solar-pumped lasers

A review of solar-pumped blackbody lasers is given which addresses their present status and suggests future research directions. The blackbody laser concept is one system proposed to scale to multimegawatt power levels for space-to-space power transmissions for such applications as onboard spacecraft electrical or propulsion needs. Among the critical technical issues are the scalability to high powers and the laser wavelength which impacts the transmission optics size as well as the laser-to-electric converter at the receiver. Because present blackbody solar-pumped lasers will have laser wavelengths longer than 4 microns, simple photovoltaic converters cannot be used, and transmission optics will be large. Thus, future blackbody laser systems should emphasize near visible laser wavelengths.

Deyoung, R. J.↗

High-speed synchrotron X-ray imaging of directed energy deposition of titanium: effects of processing parameters on the formation of entrapped-gas pores

Laser based directed energy deposition (DED) is a competitive method for repairing and remanufacturing metallic parts used in numerous industries including aerospace and biomedical. However, the numerous dynamic phenomena associated with the DED process often result in defects such as entrapped-gas pores, lack of fusion, and undesirable anisotropic properties. The entrapped-gas pore, being one of the most common issues, not only influences melt-pool dynamics but also reduces the fabrication quality and mechanical properties of parts fabricated by the DED process. To reduce and further understand this issue, the real-time observation of the pore formation process needs to be studied first. To directly observe the phenomena in the melt pool, high-speed techniques are needed because rapid solidification leads to rapid pore formation and movement. In-situ high-speed X-ray has been proven to be an effective method in investigating the melt pool dynamics and pore formation mechanisms in the laser powder bed fusion process, in which the fabrication process is quite different from that in DED. Here, the high-speed X-ray method is extended to study the formation of entrapped-gas pores. The real-time formation and quantitative analysis of pores under each set of processing parameters (particle velocity, laser power, and spot welding dwelling time of stationary laser) in the DED process are investigated. We found that the DED with a higher particle velocity (3.19 m/s) produced a smaller average pore size of 27.8 µm and a lower pore area fraction of 0.52%. The DED under lower laser power (156 W) generated a smaller average pore size of 20.3 µm and a lower pore area fraction of 1.94%. The shorter dwelling time (10 ms) benefited the decrease of both average pore size and pore area fraction.

Defect↗

Particle deceleration for collective QED signatures

Frequency upshifts have been proposed as a first experimental signature of collective effects in quantum electrodynamic cascade generated electron–positron pair plasmas. Since the high effective masses of generated pairs will reduce any frequency change, stopped pairs at a minimal Lorentz factor in the lab frame were thought to be the dominant contribution to the laser upshift. However, we demonstrate that only considering stopped particles unduly neglects the contributions of particles re-accelerated in the laser propagation direction. Re-accelerated particles should, on a per particle basis, affect the laser more strongly and over a much longer timescale. To maximize particle contributions to the laser upshift, we consider a Laguerre–Gaussian (LG) mode laser beam to better reflect generated pairs. Furthermore, the LG mode does not have an advantage in particle deceleration and re-acceleration when compared against a Gaussian beam, but the LG mode can maintain particle contributions for a longer duration, allowing for more pair density accumulation. Deceleration with a structured beam to keep pairs within the laser should create a larger upshift, thereby lowering the demands on the driving laser.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Optimization of Rocket Engine Components using Multi-Metallic Additive Manufacturing

Additive manufacturing (AM) is advancing many applications of component design for liquid rocket engines. AM has been demonstrated in various rocket component applications using a variety of monolithic metal alloys, many of which are traditional alloys for extreme environments. NASA and industry partners have focused in recent years to advance processing to create bimetallic and multicomponent AM processes and materials. The role of multi-metallic AM offers advantages since it can further optimize weight, optimize reliability and performance by increasing the strength to weight ratio of a component, and can optimize materials for various engineering requirements. NASA’s Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) project has designed and manufactured a series of additively manufactured (AM) coupled combustion chambers, nozzles, and other engine components to advance new AM processes and materials with the goal of reducing cost and schedule for engine manufacturing. These designs incorporated multimetallic AM, which further enabled carbon-fiber composite overwrap to reduce overall thrust chamber assembly (TCA) mass. Various AM processes were demonstrated on these components using a copper-based alloy/superalloy bimetallic solution. The AM processes being explored individually and in combination for bimetallic applications include Laser Powder Bed Fusion (L-PBF), Laser Powder Directed Energy Deposition (LP-DED), and cold spray. The combination of bimetallic material combinations explored in this research include GRCop-based alloys and superalloys, Inconel 625 or NASA HR-1. One unique development that will be presented is the combustion chamber and nozzle as a single component by using freeform integrated DED to build the nozzle directly onto the aft end of the chamber. The various aspects of the additive manufacturing processes and challenges, materials characterization and mechanical testing, and hot-fire testing of bimetallic components in a relevant rocket engine environment will be discussed.

Additive Manufacturing↗

Receiver performance of laser ranging measurements between the Lunar Observer and a subsatellite for lunar gravity studies

The optimal receiver for a direct detection laser ranging system for slow Doppler frequency shift measurement is shown to consist of a phase tracking loop which can be implemented approximately as a phase lock loop with a 2nd or 3rd order loop filter. The laser transmitter consists of an AlGaAs laser diode at a wavelength of about 800 nm and is intensity modulated by a sinewave. The receiver performance is shown to be limited mainly by the preamplifier thermal noise when a silicon avalanche photodiode is used. A high speed microchannel plate photomultiplier tube is shown to outperform a silicon APD despite its relatively low quantum efficiency at wavelengths near 800 nm. The maximum range between the Lunar Observer and the subsatellite for lunar gravity studies is shown to be about 620 km when using a state-of-the-art silicon APD and about 1000 km when using a microchannel plate photomultiplier tube in order to achieve a relative velocity measurement accuracy of 1 millimeter per second. Other parameters such as the receiver time base jitter and drift also limit performance and have to be considered in the design of an actual system.

Davidson, Frederic M.↗

Measurement of directional muon beams generated at the Berkeley Lab Laser Accelerator

We present the detection of directional muon beams produced using a PW laser facility at the Lawrence Berkeley National Laboratory. The muon source is a multi-GeV electron beam generated in a laser-plasma accelerator interacting with a high- converter target. The GeV photons resulting from the interaction are converted into a high-flux, directional muon beam via pair production. By employing scintillators to capture delayed events, we were able to identify the produced muons and characterize the source. Using theoretical knowledge of the muon production process combined with simulations that are in excellent agreement with the experiments, we demonstrate that laser-plasma accelerators have the capability of generating electron beams with characteristics suitable to produce GeV-scale muons that offer unique advantages with respect to the cosmic background. Laser-plasma-accelerator-based muon sources can therefore enhance muon imaging applications thanks to their compactness, directionality, and high yields, which reduce the exposure time by orders of magnitude compared to cosmic ray muons. Using the eant4-based simulation code we developed to gain insight into the experimental results, we can design future experiments and applications based on LPA-generated muons.

Terzani, Davide↗

Nuclear activation analysis of zirconium-90 isomeric and ground-state reactions at the OMEGA Laser Facility

Nuclear activation is a well-established technique for inferring neutron yields in laser direct-drive deuterium–tritium (DT) and deuterium–deuterium (D 2 ) implosions at the OMEGA Laser Facility. Zirconium has long been considered an excellent candidate for measuring DT neutron fusion yields by observing decays of the 90 Zr(n,2n) 89 Zr ground-state reaction. As it has a higher energy threshold than present activation detectors utilizing copper, zirconium provides a means to infer primary neutron yields that are less susceptible to being skewed due to neutron scattering within the experimental environment. However, with a 78.41-h half-life, it is not operationally practical to utilize this reaction for OMEGA experiments, which have a 1-h shot cycle. Zirconium’s 90 Zr(n,2n) 89 mZr reaction presents itself as a viable candidate to infer neutron yields within a shot cycle, given its half-life of 4.16 min. Here, we present an overview of the approach and methodology, utilizing first principles techniques, to infer the primary neutron yields from OMEGA DT fusion experiments by using both the isomeric and the ground-state reaction. Yields inferred from both reactions are compared, which are in good agreement between the two.

Activation analysis↗

Quaternary pulse position modulation electronics for free-space laser communications

The development of a high data-rate communications electronic subsystem for future application in free-space, direct-detection laser communications is described. The dual channel subsystem uses quaternary pulse position modulation (QPPM) and operates at a throughput of 650 megabits per second. Transmitting functions described include source data multiplexing, channel data multiplexing, and QPPM symbol encoding. Implementation of a prototype version in discrete gallium arsenide logic, radiofrequency components, and microstrip circuitry is presented.

Budinger, J. M.↗

Quaternary pulse position modulation electronics for free-space laser communications

The development of a high data-rate communications electronic subsystem for future application in free-space, direct-detection laser communications is described. The dual channel subsystem uses quaternary pulse position modulation (GPPM) and operates at a throughput of 650 megabits per second. Transmitting functions described include source data multiplexing, channel data multiplexing, and QPPM symbol encoding. Implementation of a prototype version in discrete gallium arsenide logic, radiofrequency components, and microstrip circuitry is presented.

Budinger, J. M.↗

Utilization of Additive Manufacturing for the Rapid Prototyping of C-Band Radiofrequency Loads

Additive manufacturing is a versatile technique that shows promise in providing quick and dynamic manufacturing for complex engineering problems. Research has been ongoing into the use of additive manufacturing for potential applications in radiofrequency (RF) component technologies. Here, we present a method for developing an effective prototype load produced from 316L stainless steel on a direct metal laser sintering machine. The model was tested using simulation software to verify the validity of the design. The load structure was manufactured by an online digital manufacturing company, showing the viability of using easily accessible tools to manufacture RF structures. The produced load was able to produce an S11 value of −22.8 dB at a C-band frequency of 5.712 GHz while under a vacuum. In a high-power test, the load was able to terminate a peak power of 8.1 MW. The discussion includes future applications of the present method and how it will help to improve the implementation of future accelerator concepts.

36 MATERIALS SCIENCE↗

Radio Frequency Properties of a 3D Printed Klystron Circuit

The manufacturing of active RF devices like klystrons is dominated by expensive and time-consuming cycles of machining and brazing. In this article, we characterize the RF properties of X-band klystron cavities and an integrated circuit manufactured with a novel additive manufacturing process. Parts are 3D printed in 316 L stainless steel with direct metal laser sintering, electroplated in copper, and brazed in one simple braze cycle. Stand-alone test cavities and integrated circuit cavities were measured throughout the manufacturing process. The un-tuned cavity frequency varies by less than 5% of the intended frequency, and Q factors reach above 1200. A tuning study was performed, and unoptimized tuning pins achieved a tuning range of 138 MHz without compromising Q. Klystron system performance was simulated with as-built cavity parameters and realistic tuning. Together, these results show promise that this process can be used to cheaply and quickly manufacture a new generation of highly integrated high power vacuum devices.

3D printing↗

A Sustainability-Based Expert System for Additive Manufacturing and CNC Machining

The objective of this research study is to develop a set of expert systems that can aid metal manufacturing facilities in selecting binder jetting, direct metal laser sintering, or CNC machining based on viable products, processes, system parameters, and inherent sustainability aspects. For the purposes of this study, cost-effectiveness, energy, and auxiliary material usage efficiency were considered the key indicators of manufacturing process sustainability. The expert systems were developed using the knowledge automation software Exsys Corvid ® V6.1.3. The programs were verified by analyzing and comparing the sustainability impacts of binder jetting and CNC machining during the fabrication of a stainless steel 316L component. According to the results of this study, binder jetting is deemed to be characterized by more favorable indicators of sustainability in comparison to CNC machining, considering the fabrication of components feasible for each technology.

36 MATERIALS SCIENCE↗

Location-Specific Microstructures and Properties of Haynes 282 Alloy with Laser-Wire DED Processing

In this work, the location-specific microstructures in terms of grain morphology, texture, γ′ precipitates, carbides, and residual strains were investigated in a series of laser-wire direct energy deposition (LW-DED) Haynes 282 alloys with varied processing parameters. A bimodal grain distribution was found in these as-printed and heat-treated alloys with columnar grains within the layers and fine equiaxed grains at the interlayer regions. Dominant <001> texture along the build direction with more obvious <111> orientation preference exists at the bottom layers, compared to the top layers. The gradient γ′-precipitates size distribution contributes predominantly to the observed gradient hardness distribution in the as-printed samples. The heat-treated 282 exhibit comparable yield strengths to those conventionally-processed counterparts, while the observed small deviation in their yield strengths is attributed to the Hall-Petch effect. This work establishes the correlation between location-specific microstructures and mechanical properties, providing valuable insights into future printing parameters and heat-treatment optimization.

Haynes 282↗

Supersonic-nitrogen flow-field measurements with the resonant Doppler velocimeter

The application of the resonant Doppler velocimeter (RDV) for obtaining the mean velocity, temperature, and pressure measurements and flow-field visualization in a supersonic free nitrogen jet is reported. This method utilizes laser-induced fluorescence to determine the spectral absorption of an atomic or molecular species seeded into the flow. A narrow linewidth tunable laser is directed into the flow and the total fluorescence from any point is obtained as the laser is tuned. The velocity of the flow is obtained from the Doppler shifted absorption frequency, and the temperature and pressure of the gas are determined from line broadening measurements. Results are presented for the use of this technique to determine the velocity, temperature, and pressure of the flow of sodium atoms seeded into a supersonic nitrogen jet. It is concluded that the visible signal is sufficiently intense for spatially resolved flow visualization purposes.

Cheng, S.↗

Semiconductor Laser With Two-Dimensional Beam Steering

Modification of monolithic semiconductor injection laser capable of one-dimensional electronic beam steering enables deflection of beam in second direction. Such laser chip provides beam pointing or raster scanning for applications in optical communications, data processing, image scanning, and optical ranging.

Katz, J.↗

Hot-Fire Testing Results of Additively Manufactured NASA HR-1 towards Large Scale Implementation of Channel Wall Nozzles

Additive manufacturing (AM) has provided new design and manufacturing opportunities to reduce cost and schedules, consolidate parts, and optimize performance. One technique being evaluated is Laser Powder Directed Energy Deposition (LP-DED), which provides a significant increase in scale compared to Laser Powder Bed Fusion (L-PBF). NASA along with industry partners have been developing the LP-DED process to demonstrate internal channel geometry and development components for use in liquid rocket engine channel cooled nozzles. One material that has been the focus of this development is NASA HR-1, an Iron-Nickel based superalloy optimized for use in high pressure hydrogen environments. Material properties and process characterization has been completed on the high density thin-wall material in addition to advancements of the supply chain. NASA has also completed fabrication of several subscale and full scale channel wall nozzles in LP-DED NASA HR-1 and completed hot-fire testing. This includes refinement of the process to produce thin-walls and various channel geometries to meet the requirements for channel wall nozzle applications. This paper will provide an overview of the LP-DED process development, material characterization and properties, component manufacturing, and hot-fire testing. Hot-fire testing was completed for a lander-class 7K-lbf thrust chamber using Liquid Oxygen (LOX)/Methane. The design overview and results from hot-fire testing will be presented in addition to hardware development for future testing on 2K-lbf and 35k-lbf thrust chambers and large-scale manufacturing technology demonstrators.

Paul Gradl↗