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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 OSTI2022

Fabrication of silicon-tipped fiber-optic temperature sensors using aerogel-assisted glass soldering with precise laser heating

We demonstrate the fabrication of fiber-optic Fabry–Perot interferometer (FPI) temperature sensors by bonding a small silicon diaphragm to the tip of an optical fiber using low melting point glass powders heated by a 980 nm laser on an aerogel substrate. The heating laser is delivered to the silicon FPI using an optical fiber, while the silicon temperature is being monitored using a 1550 nm white-light system, providing localized heating with precise temperature control. The use of an aerogel substrate greatly improves the heating efficiency by reducing the thermal loss of the bonding parts to the ambient environment. A desirable temperature for bonding can be achieved with relatively small heating laser power. The bonding process is carried out in an open space at room temperature for convenient optical alignment. The precise temperature control ensures minimum perturbation to the optical alignment and no induced thermal damage to the optical parts during the bonding process. For demonstration, we fabricated a low-finesse and high-finesse silicon FPI sensor and characterized their measurement resolution and temperature capability. The results show that the fabrication method has a good potential for high-precision fabrication of fiber-optic sensors.

Sheng, Qiwen↗
DOE OSTI2023

Microstructural evolution of rapidly solidified hypoeutectic Al 10Cu alloy during non-isothermal annealing transients induced by nano-second laser pulses

The evolution of characteristic nonequilibrium features presenting in morphologically distinct regions of rapid solidification (RS) microstructures in a hypoeutectic Al—10Cu (atomic %) in response to non-isothermal annealing transients has been studied by transmission electron microscopy (TEM). The capabilities of the Movie-Mode Dynamic TEM (MM-DTEM) instrument were used to expose select regions of the RS microstructure to sequences of rapid heating and cooling transients induced by nanosecond laser pulses while permitting in-situ observation. Partial melting, microstructural scale coarsening, morphological changes of the nonequilibrium features in the multi-phase RS microstructure, and solid-state phase transformation were observed. Heterogeneous nucleation of nanoscale θ-Al 2 Cu phase involved metastable supersaturated α-Al and the θ'-Al 2 Cu phases, establishing different sets of orientation relationships for the stable θ-Al 2 Cu and α-Al phases. Replacement of banded morphology grains that formed under conditions driven farthest from equilibrium by an equiaxed nanocrystalline structure comprised of α-Al phase, the primary solidification product, and an intergranular network of Al 2 Cu crystals has been attributed to local remelting. Here the experimental approach explored, permitted discovery of mechanistic details of location-specific transformation pathways activated in the multi-phase RS microstructure of hypoeutectic Al—Cu during subsequent nonisothermal transients.

36 MATERIALS SCIENCE↗
NASA NTRS2020

Ultrafast Melting at Metal-Semiconductor Interfaces: A Molecular Dynamics Study

Quantifying the thermodynamics of interfacial melting is important for several applications such as laser machining and designing radiation hardened electronic devices. Due to the short time and length scales that are involved in the process, molecular simulations provide an ideal path for understating the interfacial melting phenomena. In this work we investigate tungsten (W) – silicon carbide (SiC) interfaces which are relevant in modern high-power electronic devices. Classical molecular dynamics simulations along with the two-temperature model (TTM) were used to study the radiation induced melting of the interface while a neural network-based machine learning framework was used to track the transient re-crystallization process. The damage endured by the semiconductor at the interface following the radiation event is discussed in detail while the re-crystallization of the metal is described in terms of the classical nucleation theory.

Ashwin Ravichandran↗
DOE OSTI2025

Establishing a process-structure-property-performance framework for SLS additive manufacturing through integrated multiscale modeling

This study presents a comprehensive suite of high-fidelity computational models that integrate multiscale and multiphysics simulations to capture the full Selective Laser Sintering (SLS) additive manufacturing process—from initial melting and solidification to mechanical response under external loads. Process simulations are linked with mechanical analysis through Representative Volume Elements (RVEs), establishing a process-structure–property-performance framework. The interaction between laser light and polyamide 12 (PA12) powder is modeled, accounting for laser characteristics and the optical, thermal, and geometrical properties of the powder. The heat source is incorporated into a heat transfer model, coupled with crystallization kinetics and densification models to predict material density and crystallinity. The porosity distribution from the densification model and crystallinity interpolated from experimental data are used to construct the RVEs. A multi-mechanism constitutive model is then calibrated using mechanical tests to predict the stress–strain response. Simulation results show good agreement with experimental data in terms of porosity, crystallinity, and mechanical performance when sufficient laser power (62 W or higher) is used. This research supports the inverse design of 3D-printed structures by introducing a high-fidelity framework that combines multiscale and multiphysics modeling with experimental calibration for predictive and performance-driven additive manufacturing.

SLS↗
DOE OSTI2025

Revealing mechanisms of processing defect mitigation in laser powder bed fusion via shaped beams using high-speed X-ray imaging

The laser powder bed fusion (LPBF) process utilizing a focused Gaussian-shaped beam faces challenges, including pore formation, melt pool fluctuation and liquid spattering. While beam shaping technology has been explored as a potential approach for defect mitigation, the beam-matter interaction dynamics during melting with shaped beams remain unclear. Here, we report the direct observation of ring-shaped beam-matter interaction dynamics, including pore formation, melt pool fluctuation and liquid spattering, and unveil defect mitigation mechanisms in ring-shaped beam laser powder bed fusion process. Here, we find that, by spatially manipulating incident laser rays, the ring-shaped beam controls keyhole morphology, thereby managing the distribution of the reflected rays. This manipulation can effectively eliminate the formation of an unstable cavity at the keyhole tip, stabilizing the keyhole and mitigating keyhole pores. This enhanced keyhole stability effectively reduces the melt pool fluctuation, the formation of liquid breakup induced spatters and liquid droplet colliding induced large spatters in the laser powder bed fusion process. Additionally, the high-energy forefront of the ring-shaped beam effectively melts the powder bed, reducing agglomeration liquid spatter in the laser powder bed fusion process. The discovered defect mitigation mechanisms may guide the design of beam shaping strategies for simultaneously increasing the quality and productivity of metal additive manufacturing.

Beam shaping↗
NASA NTRSDate not supplied

Laser Angle of Incidence Effects on in-Situ Consolidation of Automated Fiber Placement of Polyaryletherketone Composites

NASA and Electroimpact, Inc. ®†† in conjunction with other U.S. industry partners are performing research as a part of the NASA High-rate Composites for Aircraft Manufacturing (HiCAM) Project to fabricate thermoplastic panels using automated fiber placement (AFP) to increase manufacturing rates of aircraft structural composites. This work focuses on evaluating the in-situ consolidation AFP of thermoplastics (ICAT) process. Previous studies of the ICAT process using semi-crystalline, polyaryletherketone (PAEK) slit-tape have resulted in an adequate degree of intimate contact between plies; however, the resulting interlaminar strength have been less than laminates fabricated in an autoclave. To improve these properties, the effect of reducing the laser angle of incidence (AoI) during placement to increase the degree of auto-hesion was evaluated. The AoI of the laser assisted AFP head was varied between 12° and 16° to fabricate multiple quasi- isotropic and unidirectional test panels. Physics-based thermal models developed at the NASA Langley Research Center were utilized to predict the temperature profile. Laminate processing temperature was measured experimentally, and panel quality was evaluated by both non- destructive evaluation (NDE) as well as destructively by photo-microscopy. The effect on interlaminar strength was determined by short beam strength testing. Test results of carbon fiber laminates fabricated by ICAT using polyetheretherketone (PEEK), polyetherketoneketone (PEKK), and low-melt polyaryletherketone (LM-PAEK) at various laser angles of incidence, placement temperatures and placement speeds are presented.

Laser↗
NASA NTRSDate not supplied

Laser Angle of Incidence Effects on in-Situ Consolidation of Automated Fiber Placement of Polyaryletherketone Composites

NASA and Electroimpact, Inc. ® in conjunction with other U.S. industry partners are performing research as a part of the NASA High-rate Composites for Aircraft Manufacturing (HiCAM) Project to fabricate thermoplastic panels using automated fiber placement (AFP) to increase manufacturing rates of aircraft structural composites. This work focuses on evaluating the in-situ consolidation AFP of thermoplastics (ICAT) process. Previous studies of the ICAT process using semi-crystalline, polyaryletherketone (PAEK) slit-tape have resulted in an adequate degree of intimate contact between plies; however, the resulting interlaminar strength have been less than laminates fabricated in an autoclave. To improve these properties, the effect of reducing the laser angle of incidence (AoI) during placement to increase the degree of auto-hesion was evaluated. The AoI of the laser assisted AFP head was varied between 12° and 16° to fabricate multiple quasi-isotropic and unidirectional test panels. Physics-based thermal models developed at the NASA Langley Research Center were utilized to predict the temperature profile. Laminate processing temperature was measured experimentally, and panel quality was evaluated by both non-destructive evaluation (NDE) as well as destructively by photo-microscopy. The effect on interlaminar strength was determined by short beam strength testing. Test results of carbon fiber laminates fabricated by ICAT using polyetheretherketone (PEEK), polyetherketoneketone (PEKK), and low-melt polyaryletherketone (LM-PAEK) at various laser angles of incidence, placement temperatures and placement speeds are presented.

Thermoplastic Composites↗
DOE OSTI2026

Which way does the dendrite grow? Competition among epitaxy, preferred growth direction, and thermal gradients in powder bed fusion additive manufacturing

The as-processed microstructure of metal alloy parts manufactured through laser powder bed fusion (LPBF) is heavily derived from the cellular dendritic solidification. The growth direction of dendrites within the melt pool is determined through competition among epitaxial growth, preferred growth directions, and maximum thermal gradients. However, the dominant factor and the specific role of each in developing melt pool microstructures remain unknown. Here, in this study, we performed single laser track scans on an SS316L single crystal substrate and combined experimental characterization of microstructure and crystal orientations with Computational Fluid Dynamics simulations of thermal gradients to evaluate the role of each factor in determining dendritic growth direction and evolution. Our results reveal that epitaxial growth dominates microstructure development by preferentially growing along a single 〈100〉 variant of the single crystal substrate adjacent to the melt pool boundary. Under LPBF’s highly curved and rapidly evolving thermal field, this preferential dendrite variant selection and its continued growth from the melt pool boundary to the centerline are governed by the local temperature gradient magnitude at the solid-liquid interface, rather than by the instantaneous maximum temperature gradient direction alone. Using these findings, we successfully predict changes in the dendrite growth direction with changing laser scan direction on a single crystal substrate, and show that the geometric melt pool centerline can deviate from the microstructural centerline because asymmetric local temperature gradient magnitudes transiently limit growth, resulting in different dendrite travel distances on each side of the melt pool.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Selective Deposition and Fusion of AISI 316L: An Additive Manufacturing Process for Space Environments via Direct Ink Writing and Laser Processing

Unlocking the potential of additive manufacturing (AM) for space exploration hinges on overcoming key challenges, notably the ability to manufacture or repair parts on-site during exploration missions with consideration of quality, feedstock utilization, and challenges involved in microgravity environments. While there are multiple efforts to investigate the use of existing metal AM processes such as powder bed fusion (PBF), directed energy deposition (DED), and filament-based material extrusion, each process comes with a different set of challenges in space environments. Here, in this work, we introduce a new AM method that integrates the benefits of direct ink writing (DIW) to selectively deposit metallic pastes with laser-based processing to locally debind and subsequently melt and fuse metal powder, layer by layer, enabling the manufacturing of AISI 316L samples with densities exceeding 99.0%. The impact of process parameters on single-track dimensions, surface morphology, and porosity was characterized. The efficacy of laser debinding was assessed via secondary-ion mass spectrometry, permitting the carbon content to be estimated at 0.0152%, which is safely below the acceptable limit (0.03 wt%) for AISI 316L.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Shock compression of silver to 300 GPa: Wave profile measurements and melting transition

Recent in-situ x-ray diffraction (XRD) measurements on laser-shock compressed Ag foils demonstrated a face-centered-cubic to body-centered-cubic transformation at ~150 GPa and melting between 172 and 197 GPa [Phys. Rev. Lett. 124, 235701 (2020)]. As a complement to the XRD work, we conducted plate impact experiments to obtain shock velocity and wave profile measurements on thicker Ag samples shock-compressed to peak stresses between 30 and 300 GPa. The shock velocity–particle velocity results were fitted very well by a linear relation over the entire stress range, providing an accurate determination of the Ag Hugoniot (locus of the stress-volume states achieved under shock compression). For peak stresses below 187 GPa and above 210 GPa—corresponding to the solid and liquid phases, respectively—the wave profiles show clean single waves. No wave profile features related to the fcc-bcc transformation at ~150 GPa were observed, implying minimal volume change for the transformation. For stresses between 187 and 210 GPa, an initial jump was followed by a time-dependent increase in the particle velocity (20–80 ns risetime) to the peak state—corresponding to the solid-liquid mixed phase response. Unlike the solid and liquid response, the mixed-phase response cannot be readily analyzed analytically. Instead, numerical simulations incorporating an accurate multiphase equation of state for Ag—not currently available—are required to analyze the wave profiles measured at 187–210 GPa stresses. Furthermore, the present work shows the potential for using wave profile measurements to examine the melting transition under shock compression.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2025

Electronic Melting of Silicon in Nanostructures using X-ray Forbidden Bragg Reflections

Abstract We carried out a short beamtime at the Pohang Accelerator Laboratory x-ray Free Electron Laser to perform a pump-probe (PP) laser excitation diffraction experiment on the silicon (222) forbidden Bragg peak. To limit the x-ray penetration, we used a “device layer” silicon film wafer bonded to a silicon substrate. The sample, specially fabricated by MEMC Electronic Materials, had a Si(100) substrate bonded to a 170 nm Si(100) film rotated at 45° for crystallographic isolation. A second sample was reactive-ion-etched down to 52 nm thickness. In the silicon lattice, the covalent bonds are seen exclusively at the 222 reflection. Upon laser excitation, these electrons are expected to be excited to the valence band on femtosecond electronic time scales. The Si(222) reflection is therefore expected to be extinguished on this fast time scale, while the electron–phonon coupled acoustic response is determined by the lattice dynamics. The latter is determined by the speed of sound over the device thickness, which is in the mid-picosecond range.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2021

Sensitivity of additively manufactured AA7075 to variation in feedstock composition and print parameters

Here we developed a combined finite element and CALPHAD based model of the Laser Powder Bed Fusion (LPBF) process for AA7075 alloy that considers the effect of feedstock composition and print parameters. A single-pass of a laser on a layer of AA7075 alloy powder has been considered. Sensitivity of temperature evolution and melt pool geometry to variation in the stoichiometry of the feedstock powder and laser source characteristics have been studied. Our results indicate that deviation (up to 10%) of the feedstock composition from the AA7075 raises the maximum temperature and increases melt pool size. Excess Cu content shows the largest melt pool width and depth among all the cases. The peak temperature is higher than the standard feedstock composition in all cases, except when the Cu concentration is reduced. Increasing the scan power also results in a higher peak temperature and a larger melt pool size. Furthermore, the temperature's rise time increases by lowering the scan speed.

42 ENGINEERING↗
DOE OSTI2020

Laser-metal interaction dynamics during additive manufacturing resolved by detection of thermally-induced electron emission

In situ monitoring is required to improve the understanding and increase the reliability of additive manufacturing methods such as laser powder bed fusion (LPBF). Current diagnostic methods for LPBF capture optical images, X-ray radiographs, or measure the emission of thermal or acoustic signals from the component. Herein, a methodology based on the thermal emission of electrons - thermionic emission - from the metal surface during LPBF is proposed which can resolve laser-material interaction dynamics. The high sensitivity of thermionic emission to surface temperature and surface morphology is revealed to enable precise determination of the transition between conduction and keyhole mode melting regimes. Increases in thermionic emission are correlated to laser scanning conditions that give rise to pore formation and regions where surface defects are pronounced. The information presented here is a critical step in furthering our understanding and validation of laser-based metal additive manufacturing.

36 MATERIALS SCIENCE↗
NASA NTRS2001

Laser Materials Processing for NASA's Aerospace Structural Materials

Lasers are useful for performing operations such as joining, machining, built-up freeform fabrication, and surface treatment. Due to the multifunctional nature of a single tool and the variety of materials that can be processed, these attributes are attractive in order to support long-term missions in space. However, current laser technology also has drawbacks for space-based applications. Specifically, size, power efficiency, lack of robustness, and problems processing highly reflective materials are all concerns. With the advent of recent breakthroughs in solidstate laser (e.g., diode-pumped lasers) and fiber optic technologies, the potential to perform multiple processing techniques in space has increased significantly. A review of the historical development of lasers from their infancy to the present will be used to show how these issues may be addressed. The review will also indicate where further development is necessary to realize a laser-based materials processing capability in space. The broad utility of laser beams in synthesizing various classes of engineering materials will be illustrated using state-of-the art processing maps for select lightweight alloys typically found on spacecraft. Both short- and long-term space missions will benefit from the development of a universal laser-based tool with low power consumption, improved process flexibility, compactness (e.g., miniaturization), robustness, and automation for maximum utility with a minimum of human interaction. The potential advantages of using lasers with suitable wavelength and beam properties for future space missions to the moon, Mars and beyond will be discussed. The laser processing experiments in the present report were performed using a diode pumped, pulsed/continuous wave Nd:YAG laser (50 W max average laser power), with a 1064 nm wavelength. The processed materials included Ti-6AI-4V, Al-2219 and Al-2090. For Phase I of this project, the laser process conditions were varied and optimized to see the effects on melt-quenching, cladding/alloying (using the pre-placed powder technique), and cutting. Key parameters such laser power, pulse repetition frequency, process speed, and shield gas flow and the observed process characteristics such as plasma formation during laser/material interaction, have been reported for all experimental runs. Preliminary materials characterization of select samples was carried out using various microscopy, diffraction, spectroscopy and microhardness test methods, and reported. Select nitridation results of Ti-6AI-4V using nitrogen assist gas indicated the successful formation of hard titanium nitrides with much higher hardness (2180 kg/sq mm). A cost-effective and simple powder delivery system has been successfully fabricated for the further experimentation in Phase H.

Nagarathnam, Karthik↗
DOE OSTI2021

Effects of Hydrogen on the Phase Relations in Fe-FeS at Pressures of Mars-Sized Bodies

The large radius, and therefore low density, of the Martian core found in the InSight mission data analysis highlights the importance of considering other light elements besides sulfur (S), which has been considered as the main light element for Mars for decades. Hydrogen (H) is abundant in the solar system and becomes siderophile at high pressures. Although Fe-S and Fe-H systems have been studied individually, the Fe-S-H ternary system has only been investigated up to 16 GPa and 1723 K. We have investigated the Fe-S-H system at pressures and temperatures (P-T) relevant to the cores of Mars-sized planets (up to 45 GPa and well above the melting temperature of FeS) in the laser-heated diamond anvil cell combined with in situ synchrotron X-ray diffraction. Here we found that sufficient hydrogen leads to the disappearance of Fe 3 S at high P-T. Instead, separate Fe-H and Fe-S phases appear at 23–35 GPa. At pressures above 35 GPa, we found a new phase appearing while Fe-S phases disappear and Fe-H phases remain. Our analysis indicates that the new phase likely contains both S and H in the crystal structure (tentatively FeS x H y where x ≈ 1 and y ≈ 1). The observed pressure-dependent changes in the phase relation may be important for understanding the structure and dynamics of the Martian core and the cores of Mars-sized exoplanets.

58 GEOSCIENCES↗
NASA NTRS1974

Heat Pipe Technology: A bibliography with abstracts

This bibliography lists 149 references with abstracts and 47 patents dealing with applications of heat pipe technology. Topics covered include: heat exchangers for heat recovery; electrical and electronic equipment cooling; temperature control of spacecraft; cryosurgery; cryogenic, cooling; nuclear reactor heat transfer; solar collectors; laser mirror cooling; laser vapor cavitites; cooling of permafrost; snow melting; thermal diodes variable conductance; artery gas venting; and venting; and gravity assisted pipes.

Source record↗
NASA NTRS1996

Argon-40/Argon-39 Age Spectra of Apollo 17 Highlands Breccia Samples by Laser Step Heating and the Age of the Serenitatis Basin

We have obtained high-resolution (21-63 steps) Ar-40/Ar-39 age spectra using a continuous laser system on 19 submilligram samples of melt rocks and clasts from Apollo 17 samples collected from the pre-Imbrian highlands in the easternmost part of the Serenitatis basin. The samples include poikilitic melt rocks inferred to have been formed in the Serenitatis basin-forming impact, aphanitic melt rock whose compositions vary and whose provenance is uncertain, and granulite, gabbro, and melt clasts. Three of the poikilitic melts have similar age spectrum plateau ages (72395,96, 3893 +/- 16 Ma (2sigma); 72535,7, 3887 +/- 16 Ma; 76315,150, 3900 +/- 16 Ma) with a weighted mean age of 3893 +/- 9 Ma, which we interpret as the best age for the Serenitatis basin- forming impact. Published Ar-40/Ar-39 age spectrum ages of Apollo 17 poikilitic melts are consistent with our new age but are much less precise. Two poikilitic melts did not give plateaus and the maxima in their age spectra indicate ages of greater than or equal to 3869 Ma (72558,7) and greater than or equal to 3743 Ma (77135,178). Plateau ages of two poikilitic melts and two gabbro clasts from 73155 range from 3854 +/- 16 Ma to 3937 +/- 16 Ma and have probably been affected by the ubiquitous (older?) clasts and by post- formation heating (impact) events. Plateau ages from two of the aphanitic melt 'blobs' and two granulites in sample 72255 fall in the narrow range of 3850 q 16 Ma to 3869 q 16 Ma with a weighted mean of 3862 +/- 8 Ma. Two of the aphanitic melt blobs from 72255 have ages of 3883 +/- 16 Ma and greater than or equal to 3894 Ma, whereas a poikilitic melt clast (of different composition from the 'Serenitatis' melts) has an age of 3835 +/- 16 Ma, which is the upper limit for the accretion of 72255. These data suggest that either the aphanitic melts vary in age, as is also suggested by their varying chemical compositions, or they formed in the 72255 accretionary event about 3.84-3.85 Ga and older relict material is responsible for the dispersion of ages. In any case the aphanitic melts do not appear to be Serenitatis products. Our age for the Serenitatis impact shows, on the basis of the isotopic age evidence alone, that Serenitatis is greater than 20-25 Ma and probably greatr than 55-60 Ma older than Imbrium (less than or equal to 3870 Ma and probably less than or equal to 3836 Ma (Dalrymple and Ryder, 19931). Noritic granulite sample 78527 has a plateau age of 4146 +/- 17 Ma, representing a minimum age for cooling of this sample in the early lunar crust. So far there is no convincing evidence in the lunar melt rock record for basin-forming impacts significantly older than 3.9 Ga.

Dalrymple, G. Brent↗
NASA NTRS1999

Illuminating Development

Through the support of the NASA SBIR program, Control Vision, Inc. developed novel video techniques for clear, high resolution, real-time imaging of high temperature, high-energy industrial processes, such as welding, plasma arc spraying (coating), arc furnaces, metal casting and refractories (ceramics) melting. The Control Vision systems use reflected laser or strobe illumination, combined with ultra-short exposure times to create video, including the allowance of particle imaging velocimetry (PIV) of fast moving powder particles buried within a plasma stream.

Source record↗