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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 451 records · Page 25
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Integration of sensors through additive manufacturing leading to increased efficiencies of gas turbines for power generation and propulsion

To realize the full capability of additively manufactured components in complex energy systems, it is imperative to minimize early component failures during development phases and during operation. Traditional field feedback timelines and offline inspection protocols significantly reduce the design-manufacturing iteration times. To address this specific question, the project developed and demonstrated a method for the integration of sensors into complex components through additive manufacturing. The team used gas turbine engines as a platform, which meets the need of both power generation and propulsion and offer opportunities for cost reductions and efficiency increases. The innovation of this intelligent integration of sensors into complex components uniquely customized to address questions of integrity and durability for additively manufactured components. With real-time sensing data from additively manufactured components, turbine manufacturers will realize higher efficiencies, reduced component failures, and a 30-50% acceleration in product deployment of high efficiency gas turbine components due to a faster reduction in component risk assessment under actual operating conditions. This is a transformative shift towards a data-driven design and qualification of additively manufactured gas turbine components. To directly integrate sensors into additively manufactured components with all the complexities of actual hardware, powder bed fusion (direct metal laser sintering) and laser metal deposition technologies was developed. Validation took take place in two university laboratories both of which contain actual engine hardware and closely simulate a gas turbine prior to demonstrating the technology in a turbine development test. Indeed, two major technologies from this research cold impact turbine systems in the near future: (1) higher efficiency materials and designs enabled by additive manufacturing with 50% faster design to manufacturing cycle time, to enable faster time-to-market targets; and (2) integration of sensors into additively manufactured components enabling broad health and condition based prognostics for faster component and engine risk reduction.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2026

Statistical Correlation of Heliostat Pointing Deviation With Wind

This work was carried out as part of the Heliostat Consortium (HelioCon) Field Deployment subtask with the aim to develop a reduced order model framework for correlating wind speed and pointing deviation of a heliostat facet. There are only sparse field measurements of heliostat pointing deviations and accompanying wind conditions published in the literature. Heliostat test standards, such as IEC 62862-4-3, propose a suite of tests including laser pointing repeatability at wind speeds below 4 m/s, and provide technical requirements for heliostat slope and tracking deviations in coarse average wind speed bins of 4 m/s, 6 m/s, and 8 m/s. In addressing the gap of the variation of heliostat pointing deviation with wind speed, field measurements of laser pointing on a grid target and wind conditions were analyzed in this study at the Third-Party Metrology Platform at the National Laboratory of the Rockies (NLR) Flatirons Campus. Horizontal pointing deviations were found to follow a logarithmic relationship with peak wind speed, whereas vertical pointing deviations follow an exponential relationship with peak wind speed. Both horizontal and vertical pointing deviations also follow a second order polynomial relationship, as expected from the proportionality of elastic loads and deformations with the square of wind speed. The results indicate that heliostat facet pointing deviations in the vertical direction increase at a faster rate than in the horizontal direction with increasing wind speed over the tested range, however these are dependent on the heliostat structural design. Next steps are recommended for additional field measurements to confirm a linear relationship of pointing deviation with applied moment on a heliostat facet, and to distinguish between gravity-induced and wind-induced pointing deviations at different elevation angles. The derived correlations in the preliminary analysis in this report serve as a case study for heliostat developers and plant operators to estimate the wind-induced pointing deviations and their variation with peak gust wind speed. Next steps in future work would recommend higher resolution and longer duration datasets for different elevation angles and wind directions to reduce uncertainties and variance of collected laser beam spot data and their correlations with bin-averaged wind speed.

17 WIND ENERGY↗
DOE OSTI2024

A Gaussian Process-Based extended Goldak heat source model for finite element simulation of laser powder bed fusion additive manufacturing process

In this study, laser powder bed fusion (L-PBF) additive manufacturing (AM) is a key enabling technology to manufacture highly complex and integrated metallic structures. In L-PBF AM process, the melting of the metal powders and the layers underneath can be governed by either “conduction mode” or “keyhole mode”, with the keyhole mode reportedly leading to porosity and decreased strength and ductility by many studies. In part scale simulations, finite element (FE) model is often used to study the temperature distribution during printing and to predict the residual stress, where a volumetric heat flux with a Gaussian or a double ellipsoidal (Goldak) distribution is often applied as the laser heat source. However, the above heat source models can only capture the melt pool shape in the conduction mode, and fail to capture the transition to keyhole melting mode when the process parameters change. To overcome this inaccuracy, an extended Goldak heat source model is proposed by introducing a laser penetration term as a function of laser parameters obtained from a Gaussian-Process (GP) model. The model is validated by “2D pad” AlSi10Mg L-PBF experiments under a wide range of laser power, scan speed, and laser focus offset, and the results show the model successfully captures the measured melt pool shape in all conditions.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Structural and Electrocatalytic Studies of Pulsed Laser Deposited Epitaxial RuO 2 Thin Films

Two sets of high-quality epitaxial ruthenium oxide (RuO 2 ) thin films with different thicknesses were synthesized in situ on cost-competitive sapphire substrates by using a pulsed laser deposition technique. The first set of films, with a thickness of 40 nm and a sheet resistance of 15.7 Ω/□, was prepared using 2100 laser pulses, while the second set of films, with a thickness of 87 nm and a sheet resistance of 6.7 Ω/□, was prepared using 4800 laser pulses. All other deposition parameters were kept the same. The post-deposition structural and morphological measurements showed that both sets of films grew at the same growth rate, had the same crystallinity, similar grain boundary density, and slightly different surface roughness. The thicker RuO 2 films achieved an overpotential of 280 mV for the oxygen evolution reaction at a current density of 100 μA/cm 2 , comparable to or exceeding the performance of films grown on more expensive substrates. Comparatively, the thinner RuO 2 films, which have a significantly higher charge transfer resistance (250 Ω versus 100 Ω for thick films), display a higher overpotential of 320 mV. These results indicate that the lower electrical resistance of thicker films promotes charge transfer through the film body, leading to superior electrocatalytic properties.

charge-transfer↗
DOE OSTI2025

3D mesh regularization within an ALE code using a weighted line sweeping method

The Lagrangian formalism is widely used to simulate hydrodynamic responses in complex engineering applications, particularly those involving strong shock waves. However, as the mesh moves with the fluid, it can become highly distorted, requiring a regularization step. This involves constructing a new grid and remapping conservative quantities onto it to restore mesh quality. This work introduces a regularization method for block-structured meshes within a 3D ALE (Arbitrary Lagrangian-Eulerian) code. The proposed approach prevents mesh tangling while preserving the anisotropic features of the initial Lagrangian mesh. This regularization technique incorporates aspect ratio-based weights to control mesh smoothing. Unlike uniform rezoning techniques, this weighted approach maintains proximity to the Lagrangian mesh while improving mesh quality. Here, the method effectively handles concave geometries by mitigating the grid attraction phenomenon, which typically leads to mesh concentration along concave edges. Numerical experiments demonstrate its efficiency in regularizing severely deformed meshes, and its integration within the ALE framework is validated on challenging hydrodynamic test cases, including the triple point problem.

42 ENGINEERING↗
DOE OSTI2021

Enabling Multi-Material Structures of Co-Based Superalloy Using Laser Directed Energy Deposition Additive Manufacturing

Cobalt superalloys such as Tribaloys are widely used in environments that involve high temperatures, corrosion, and wear degradation. Additive manufacturing (AM) processes have been investigated for fabricating Co-based alloys due to design flexibility and efficient materials usage. AM processes are suitable for reducing the manufacturing steps and subsequently reducing manufacturing costs by incorporating multi-materials. Laser directed energy deposition (laser DED) is a suitable AM process for fabricating Co-based alloys. T800 is one of the commercially available Tribaloys that is strengthened through Laves phases and of interest to diverse engineering fields. However, the high content of the Laves phase makes the alloy prone to brittle fracture. In this study, a Ni-20%Cr alloy was used to improve the fabricability of the T800 alloy via laser DED. Different mixture compositions (20%, 30%, 40% NiCr by weight) were investigated. The multi-material T800 + NiCr alloys were heat treated at two different temperatures. These alloy chemistries were characterized for their microstructural, phase, and mechanical properties in the as-fabricated and heat-treated conditions. SEM and XRD characterization indicated the stabilization of ductile phases and homogenization of the Laves phases after laser DED fabrication and heat treatment. In conclusion, the NiCr addition improved the fabricability and structural integrity of the T800 alloy.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Fiber coupled laser ultrasound system using a single mode hollow core fiber for excitation laser: Theory and demonstration for on-machine thickness gauging

Laser ultrasound (LU) is a technique that uses a pump laser and a probe laser to optically generate and detect elastic waves in a material. Despite its advantages over traditional contact transducer-based ultrasound, industrial adoption has been limited by complex optical setups and the inability of multi-mode fibers to deliver a stable Gaussian profile for the pump laser. Here, we report a fully fiber-coupled thermoelastic LU system that uses an anti-resonant hollow-core single-mode fiber to deliver 1 mJ nanosecond pulses of 1064 nm light, while preserving the fundamental Gaussian mode (pump laser). When combined with a fiber-coupled interferometer (probe laser), a small, flexible, and environmentally robust sensor capable of optically generating and detecting high frequency broadband ultrasound is realized. We demonstrate such an LU system implemented in situ on a four-axis precision lathe. High-resolution thickness gauging is performed, before and after precision cutting, by exciting and measuring a zero-group velocity guided wave mode. The measurements are verified with ex-situ traceable coordinate measuring machine data. Mean absolute deviations of 0.1%, of nominal thickness, before cutting, and 0.2% and 0.3%, after stepped and tapered cuts, respectively, are reported. A theoretical background for thermoelastic ultrasound generation in an elastic waveguide is also presented. Attention is given to the effect of the pump laser profile on wave generation to elucidate the importance of using single-mode laser light. The fiber-coupled system demonstrated is well-suited for use in scientific and engineering sensing applications and facilitates the adoption of LU for industrial non-destructive testing.

Engineering↗
DOE OSTI2022

Coaxial laser absorption and optical emission spectroscopy of high-pressure aluminum monoxide

This work advances laser absorption spectroscopy with measurements of aluminum monoxide (AlO) temperature and column density in extreme pressure ( P > 60 bar) and temperature ( T > 4000 K) environments. Measurements of the AlO A 2 Π i – X 2 Σ + transition are made using a microelectromechanical system, tunable vertical cavity surface emitting laser (MEMS-VCSEL). Simultaneous emission measurements of the AlO B 2 Σ + – X 2 Σ + transition are made along a line of sight that is coaxial with the laser absorption. Absorption temperature fits agree with emission spectra for a T = 3200 K, P = 9 bar case. In cases with T > 4000 K, P > 60 bar, absorption fits match the ambient temperature while emission fits over-estimate it, owing to high optical depths. These data juxtapose passive and active spectroscopic methods and demonstrate the versatility of AlO laser absorption in high-pressure and high-temperature environments where experimental data remain scarce, and engineering models will benefit from refined measurements.

Daniel, K. A.↗
DOE OSTI2022

Synthesis, Crystal and Electronic Structures, Nonlinear Optical Properties, and Magnetic Properties of Two Thiophosphates: KInP 2 S 7 and KCrP 2 S 7

Two thiophosphates, KInP 2 S 7 and KCrP 2 S 7 , were structurally characterized without investigating any optical properties. Herein in this work, KInP 2 S 7 and KCrP 2 S 7 were revisited to investigate their optical and magnetic properties, respectively. Pure polycrystalline samples and crystals of KInP 2 S 7 and KCrP 2 S 7 were grown by high temperature solid state reactions, where mm-sized crystals of KCrP 2 S 7 were collected. KCrP 2 S 7 is isostructural to KInP 2 S 7 , which features a layered structure. KInP 2 S 7 and KCrP 2 S 7 possess close relationship to the layered thiophosphate M 2 P 2 S 6 (M = Fe, Co, Zn, etc.). The bonding pictures of KInP 2 S 7 were studied using the electron localization function (ELF) coupled with crystal orbital Hamilton population (COHP) calculations. The intrinsically distorted [PS 4 ] tetrahedra and [InS 6 ] octahedra are made by strong covalent P-S interactions and ionic In-S interactions, respectively. Electronic structure analysis confirmed that the optical properties of KInP 2 S 7 are mainly contributed to by [PS 4 ] tetrahedra together with small amounts of the contributions coming from [InS 6 ] octahedra. Magnetic measurement on mm-sized crystals of KCrP 2 S 7 verified that there is an antiferromagnetic transition around 21 K, and the Cr atoms are trivalent. KInP 2 S 7 is predicated to be an indirect bandgap semiconductor of 2.38 eV, which is confirmed by the UV-Vis measurement of 2.4(1) eV. KInP 2 S 7 is not a type-I phase-matching material and exhibits moderate second harmonic generation (SHG) response (0.51 × AgGaS 2 , sample of particle size of 100 µm). The laser damage threshold (LDT) of KInP 2 S 7 is very high of 5.2 × AgGaS 2 . Bandgap engineering were undergone to enhance the SHG response of KInP 2 S 7 .

36 MATERIALS SCIENCE↗
DOE OSTI2024

Direct reuse of graphite and lithium nickel manganese cobalt oxide (NMC) recovered from ultrafast-laser ablation debris in Li-ion battery electrodes

Here we demonstrate that debris collected from the ultrafast-laser ablation of graphite anodes can be directly reused in a lithium-ion battery with little to no negative effects on electrochemical performance. Further, we show that while post-ablation NMC (LiNi 0.33 Mn 0.33 Co 0.33 O) cathode debris will require additional processing before being incorporated into an electrode, its critical materials (nickel, manganese, and cobalt) are not lost during ablation and can be recovered for recycling. Pre- and post-ablation materials are characterized with a suite of diagnostics, including SEM, TEM, X-ray CT, EDS, and XRD, to study changes in material morphology, composition and crystal structure. Graphite exhibited little to no morphological or compositional changes and a slight annealing of its crystal structure. NMC underwent profound morphological and crystallographic changes, but retained its elemental composition. Finally, post-ablation materials were re-manufactured into electrodes and cycled vs lithium metal. Graphite showed equal or better capacity and Coulombic efficiency compared to pre-ablation electrodes, while the post-ablation NMC exhibited severely reduced electrochemical performance. Furthermore, we discuss the outlook for application of this work to advanced manufacturing lines that produce next-generation, laser-patterned electrodes.

25 ENERGY STORAGE↗
DOE OSTI2023

Evaluation of Flaw Detection with SLDV Methods Before/After Mechanical Patch

This report provides a summary of the testing and the experiments to evaluate the utility of laser ultrasonic testing (UT) in detecting and characterizing defects on the surface of steel plates before and after the application of an engineered composite patch for crack repair. Included are the detection and characterization of defects from a section of welded plate material taken from the Sandia National Laboratories’ full-size mockup of a spent nuclear fuel (SNF) dry storage canister which had been pre-flawed and exposed to deliquescent sea salt conditions for 2 years. The information includes a review of previously reported metallurgical characterization, and new work on detailed surface characterization of the corrosion attack using laser UT.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Demonstration of an intense lithium beam for forward-directed pulsed neutron generation

Abstract As an alternative to research nuclear reactors, a compact accelerator-driven neutron generator that uses a lithium beam driver could be a promising candidate since it produces almost no undesired radiation. However, providing an intense lithium-ion beam has been difficult, and it has been thought that the practical application of such a device would be impossible. The most critical problem of insufficient ion fluxes has been solved by applying a direct plasma injection scheme. In this scheme, a pulsed high-density plasma from a metallic lithium foil generated by laser ablation is efficiently injected and accelerated by a radio-frequency quadrupole linear accelerator (RFQ linac). We have obtained a peak beam current of 35 mA accelerated to 1.43 MeV, which is two orders of magnitude higher than a conventional injector and accelerator system can deliver.

43 PARTICLE ACCELERATORS↗
DOE OSTI2022

Unveiling the origins of work-hardening enhancement and mechanical instability in laser shock peened titanium

Laser shock-peening (LSP) produces complex gradients in microstructures and residual stresses, which enables fabrication of metallic engineering components with superior mechanical properties. In this work, we use non-destructive and spatially resolved high-energy X-ray diffraction (HE-XRD) to investigate the influences of LSP on microstructure, surface topography, and residual stress for high purity titanium plates. LSP is found to produce large compressive in-plane residual stresses near the peened surface which monotonically decay to zero about 2.5 mm below the surface. These properties were also tracked during in-situ tensile loading, allowing stress partitioning and work-hardening rates to be measured as a function of depth. The surface region is found to have the highest work-hardening rate and remain mechanically stable up to sample failure. In addition, a crystal rigid rotation along a transversal axis of about 27 & nbsp; was observed at large applied strain near the surface region, which is attributed to the formation of denser dispersed shear bands. Furthermore, a sudden drop in tensile stress was observed at a depth of similar to 160 mu m from the LSP surface, indicating the formation of a localized mechanical instability zone (LMIZ). The origin of this LMIZ could be attributed to the increase in shear stress induced by a load transfer from LSP surface due to the formation of denser dispersed shear bands. These observations indicate a localized transition in deformation behavior has occurred from dispersed shear banding to LMIZ and homogeneous deformation.

36 MATERIALS SCIENCE↗
DOE OSTI2025

UV-Enabled Defect Engineering in Multilayer GaSe and InSe and UV Writing of the Grating Pattern

III–VI post-transition-metal chalcogenides are layered semiconductor materials that exhibit direct band gaps in multilayers. Defect engineering is essential in 2D layered semiconductors for functional devices. Here, in this work, we report defect engineering in multilayer gallium selenide (GaSe) and indium selenide (InSe), where defects generated by ultraviolet (UV, 325 nm) laser irradiation result in an additional photoluminescence (PL) line. The additional PL line is due to defect-bound excitons. Characteristics of the defect emission are similar in GaSe and InSe samples subjected to UV irradiation, air annealing, and hydrostatic pressure. Two-beam UV interference was applied to create grating patterns with a periodic array of low and high densities of defects in GaSe. Density functional theory has identified the defect type in GaSe. The results provide valuable insights into defect generation and UV scribing of photonic circuits in 2D Se-based multilayers for optical integration in a 2D platform.

2D multilayered materials↗
DOE OSTI2020

Terahertz Spectroscopy of Gas Mixtures with Dual Quantum Cascade Laser Frequency Combs

Terahertz laser frequency combs based on quantum cascade lasers provide coherent, broadband, electrically pumped, THz radiation sources for use in future spectroscopic applications. In this work, we explore the feasibility of such lasers in a dual-comb spectroscopy configuration for the detection of multiple molecular samples in the gas phase. The lasers span approximately 180 GHz of optical bandwidth, centered at 3.4 THz, with submilliwatt total optical power. One of the main advantages of dual-comb spectroscopy is its high speed, which opens up the possibility for direct observations of chemical reaction dynamics in the terahertz spectral region. As a proof-of-concept, we recorded continuously evolving spectra from gas mixtures with 1 ms temporal resolution.

42 ENGINEERING↗
DOE OSTI2026

Molten pool dynamics and humping suppression in high-speed laser welding via tailored beam configurations

High-speed laser welding is essential for increasing the production rate of fuel cell fabrication. However, when the welding speed exceeds a critical limit, humping occurs and reduces the weld quality. In this study, two tailored beam configurations, including an adjustable ring mode and a dual-beam configuration, were employed to suppress humping. Computational fluid dynamics simulations were performed to elucidate the underlying suppression mechanisms. Here, the results show that, in the adjustable ring mode, humping mitigation arises from a reduced backward cross-sectional melt flow rate and a more stable molten pool. In the dual-beam configuration, humping suppression is attributed to the deceleration of melt flow, the conduction-mode behavior of the trailing beam, and the widening of the molten pool induced by the trailing laser. Furthermore, because the dual-beam configuration directly modifies the trailing molten pool dynamics, it achieves more effective humping suppression, extending the welding speed limit to 1.50 m/s, compared with 1.00 m/s for the adjustable ring mode.

08 HYDROGEN↗
DOE OSTI2022

Electrostatic powder spreading for metal powder bed fusion applications

Typical powder bed fusion processes spread each layer of powder by pushing it across the build area with a spreader bar or roller. While simple, these methods require good flowing powder and do not have the ability to place more than one powder type per layer. This naturally limits the ability to incorporate more than one material onto each powder layer in powder bed additive manufacturing processes. Here we demonstrate electrostatic powder spreading, a method to deposit a powder layer without mechanical contact with the previous layers. Electrostatic powder spreading (ESPS) uses an electric field formed between a powder container and a counter electrode to move powder particles from the container to the powder bed. We show that the rate at which powder is deposited can be controlled by adjusting the strength of the electric field. Correspondingly, the deposited layer thickness is controlled by the strength of the electric field and the recoating speed. To demonstrate the feasibility of ESPS for laser powder bed fusion powder spreading, nearly fully dense (> 99.8%) coupons were built in a commercial L-PBF machine using the ESPS setup. Finally, we achieve 2D patterning of a single layer by using an array of electrodes and switching the applied electric field on and off. ESPS represents a method to produce an arbitrary patterned multi-material powder bed without complicated powder removal steps and easy implementation into existing L-PBF machines. Furthermore, ESPS presents an opportunity to build parts with 3D gradients in material properties.

36 MATERIALS SCIENCE↗