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At least 487 records · Page 27

All sources NASA NTRS DOE OSTI

DOE OSTI2021

Fatigue of laser powder bed fusion processed 17-4 stainless steel using prior process exposed powder feedstock

The rapid pace of development seen in the metal additive manufacturing (AM) process of laser powder-bed fusion (LPBF) requires in-step advances in processes qualification to enable full-scale adoption. This particularly applies to quantifying how powder feedstock conditions impact end-component quality. Here this study examines how in-machine 17-4 stainless steel powder feedstocks are affected by prior LPBF processes, and how these effects impact subsequent builds. Examinations of powder morphology, chemistry, flowability, and rheology were conducted to characterize the powder conditions. The resultant effects of powder feedstock condition on produced component quasi-static tensile and high-cycle fatigue properties were analyzed. Fatigue life was analyzed using a reliability modeling approach that enabled a robust statistical comparison of life. Powder characteristics were found to evolve with powder exposure to prior LPBF processes, particularly in the extremes of powder size distribution and measures of bulk flow. No significant effects of these changes on tensile properties were observed. Reliability modeling methods, including the lognormal and Weibull distributions as well as the empirical survival function, are shown to be effective tools for modeling fatigue variability in LPBF manufactured components. Through these tools, fatigue life was found to be invariant with changes in powder condition.

42 ENGINEERING↗

DOE OSTI2025

Laser system design and critical technologies for the NSF OPAL project

The three-year NSF OPAL project is completing the preliminary design of a 2 x 25-PW all-optical parametric chirped-pulse amplification (OPCPA) system capable of delivering 500-J, 20-fs pulses. The design includes two Alpha beamlines that can be co-timed and pointed into two experimental areas for high-intensity research in several configurations. Additionally, a more flexible 2-PW Beta beam can be used in place of one Alpha beam to allow a wider range of focusing geometries and synchronized electron-beam generation for diverse experimental applications. Here, building on the development of the mid-scale MTW-OPAL prototype system, the NSF OPAL project also focuses on advancing essential technologies, such as large-grating fabrication techniques and actively-cooled disk amplifiers.

42 ENGINEERING↗

DOE OSTI2024

Broadband 920-nm mirror thin film damage competition

The 2023 Laser Damage conference thin-film damage competition was devoted to a survey on the state-of-the-art broadband near-IR multilayer dielectric (MLD) mirrors designed for ultra-short pulsed laser applications. The requirements for the coatings were a minimum reflection of 99.5% at 45-deg incidence angle for S-polarization from 830 nm to 1010 nm and group delay dispersion (GDD) < ± 50fs 2 . The participants were allowed to select the coating materials, coating design, and coating deposition method. Samples were damage tested at a single testing facility to enable direct comparison among the participants using a 25 ± 5 fs optical parametric chirped-pulse amplification (OPCPA) laser system operating at 5 Hz. The testing results from this set of 37 samples showed that dense coatings by ion-beam sputtering (IBS), magnetron sputtering (MS), and electron-beam ion assisted deposition (e-beam IAD) exhibited highest damage initiation onset (laser-induced damage threshold or LIDT) while e-beam coatings were low performers. In addition, multilayer coatings using tantala and/or hafnia as high index materials were top performers. Furthermore, this competition included for the first time the measurement of the damage growth onset (laser-induced damage growth threshold or LDGT). This latter performance metric plays an important role in establishing the safe operational conditions for larger aperture ultrashort pulsed lasers. Information pertaining to the morphology of the damage sites and their evolution under subsequent exposure to different laser fluences leading to damage growth is presented. Finally, not all coating samples in the survey met the GDD requirements stated above and associated measurements are discussed in the context of the present and past thin-film damage competitions focused on similar broadband near-IR MLD coatings.

23 broadband high reflectors↗

DOE OSTI2023

Engine Operating Conditions, Fuel Property Effects, and Associated Fuel–Wall Interaction Dependencies of Stochastic Preignition

This work for the Coordinating Research Council (CRC) explores dependencies on the opportunity for fuel to impinge on internal engine surfaces (i.e., fuel–wall impingement) as a function of fuel properties and engine operating conditions and correlates these data with measurements of stochastic preignition (SPI) propensity. SPI rates are directly coupled with laser–induced florescence measurements of dye-doped fuel dilution measurements of the engine lubricant, which provides a surrogate for fuel–wall impingement. Literature suggests that SPI may have several dependencies, one being fuel–wall impingement. However, it remains unknown if fuel-wall impingement is a fundamental predictor and source of SPI or is simply a causational factor of SPI. In this study, these relationships on SPI and fuel-wall impingement are explored using 4 fuels at 8 operating conditions per fuel, for 32 total test points. The fuels were directly injected at two different injection timings: an earlier injection timing that initially targets the piston crown and a later injection timing that targets the cylinder liner. At each injection timing, the engine was operated at both 90°C and 70°C coolant and lubricant temperatures, and 185 and 200 kPa absolute intake manifold pressure. This work serves as an exploratory effort to down select conditions and provide initial fuel properties of interest for a secondary study to explore fuel property specific effects on fuel-wall interaction and SPI propensity. Significant findings from this initial operating condition and fuel property exploratory work are: 1. reduced engine operating coolant and lubricant temperatures, along with 2. retarded injection timings were required to increase SPI propensity. Moreover, at these conditions some fuel specific effects were also observed; specifically, increased ethanol content increased measured dye–wall (i.e., fuel–wall) interaction. However, despite increased dye–wall interaction, the increased volatility of the ethanol containing fuels also reduced the estimated fuel retention in the top-ring zone and associated measured SPI propensity. Thus, the findings of this unique approach to explore relationships between fuel-wall impingement and SPI highlight that SPI propensity is more directly proportional to retained fuel, and not simply fuel–wall impingement. Furthermore, fuel retention was found to be directly influenced by complex fuel property and engine operating condition relationships. Either retarded injection timings and/or increased fuel volatility increased fuel wall-impingement, while less volatile fuels and/or reduced coolant temperatures increased fuel retention. Therefore, for a given operating condition, the data highlights that greater volatile fuels exhibit increased fuel wall impingement without increased fuel retention or SPI propensity, while less volatile fuels could exhibit reduced fuel-wall impingement but increased fuel retention and SPI propensity rates.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2023

Floquet engineering of strongly driven excitons in monolayer tungsten disulfide

Interactions of quantum materials with strong-laser fields can induce exotic nonequilibrium electronic states. Monolayer transition-metal dichalcogenides, a new class of direct-gap semiconductors with prominent quantum confinement, offer exceptional opportunities toward Floquet engineering of quasiparticle electron-hole states, or excitons. Strong-field driving has a potential to achieve enhanced control of electronic band structure, thus a possibility to open a new realm of exciton light-matter interactions. However, experimental implementation of strongly-driven excitons has so far remained out of reach. Here, we use mid-infrared laser pulses below the optical bandgap to excite monolayer tungsten disulfide up to a field strength of 0.3 V/nm, and demonstrate strong-field light dressing of excitons in the excess of a hundred millielectronvolt. Our high-sensitivity transient absorption spectroscopy further reveals formation of a virtual absorption feature below the 1s-exciton resonance, which is assigned to a light-dressed sideband from the dark 2p-exciton state. Quantum-mechanical simulations substantiate the experimental results and enable us to retrieve real-space movies of the exciton dynamics. Here, this study advances our understanding of the exciton dynamics in the strong-field regime, and showcases the possibility of harnessing ultrafast, strong-field phenomena in device applications of two-dimensional materials.

36 MATERIALS SCIENCE↗

NASA NTRS2019

Bimetallic Channel Wall Nozzle Development and Hot-Fire Testing Using Additively Manufactured Laser Wire Direct Closeout Technology

NASA has been developing and advancing regeneratively-cooled channel wall nozzle technology for liquid rocket engines to reduce cost and schedules associated with fabrication. One of the primary methods being advanced is Laser Wire Direct Closeout (LWDC). LWDC was developed to provide an additively manufactured laser deposited closeout of the coolant channels that also forms the structural jacket in-situ. This technique has been previously demonstrated through process development and hot-fire testing on a series of subscale nozzles at NASA Marshall Space Flight Center. The hot-fire test articles were fabricated using monolithic alloys to simplify the fabrication process. Ongoing research is being conducted to further expand use of this process for increased scale and bimetallic or multi-alloy options. The use of multi-alloys is desired to fully optimize the combination of materials in the radial and axial directions to reduce overall weight of the nozzle and allow for higher thermal and structural margins on the channel wall nozzle. NASA recently completed process development and hot-fire testing of a series of channel wall nozzles that incorporate a copper-alloy as the hotwall liner material and a superalloy and combination thereof for the structural jacket using the LWDC technique. The fabrication process was further advanced by using a multi-alloy axial joint using explosive bonding integrating a copper-alloy at the forward end of the nozzle hotwall and a stainless-alloy for the remaining length. A third alloy was then used for the channel closeout using the LWDC process. This paper will describe the process development using the LWDC process for channel closeout utilizing the multi-alloys, hardware design and results from hot-fire testing on subscale multi-alloy LWDC channel cooled nozzles.

Gradl, Paul↗

NASA NTRS2019

The ILRS: Approaching 20 Years and Planning for the Future

The International Laser Ranging Service (ILRS) was established by the International Association of Geodesy (IAG) in 1998 to support programs in geodesy, geophysics, fundamental constants and lunar research, and to provide the International Earth Rotation Service with data products that are essential to the maintenance and improvement in the International Terrestrial Reference Frame (ITRF), the basis for metric measurements of changes in the Earth and Earth–Moon system. Other scientific products derived from laser ranging include precise geocentric positions and motions of ground stations, satellite orbits, components of Earth’s gravity field and their temporal variations, Earth Orientation Parameters, precise lunar ephemerides and information about the internal structure of the Moon. Laser ranging systems are already measuring the one-way distance to remote optical receivers in space and are performing very accurate time transfer between remote sites in the Earth and in Space. The ILRS works closely with the IAG’s Global Geodetic Observing System. The ILRS develops (1) the standards and specifications necessary for product consistency, and (2) the priorities and tracking strategies required to maximize network efficiency. The service collects, merges, analyzes, archives and distributes satellite and lunar laser ranging data to satisfy a variety of scientific, engineering, and operational needs and encourages the application of new technologies to enhance the quality, quantity, and cost effectiveness of its data products. The ILRS works with (1) new satellite missions in the design and building of retroreflector targets to maximize data quality and quantity, and (2) science programs to optimize scientific data yield. Since its inception, the ILRS has grown to include forty laser ranging stations distributed around the world. The ILRS stations track more than ninety satellites from low Earth orbit (LEO) to the geosynchronous orbit altitude as well as retroreflector arrays on the surface of the Moon. Applications have been expanded to include time transfer, asynchronous ranging for targets at extended ranges, free space quantum telecommunications, and the tracking of space debris. Laser ranging technology is moving to lower energy, higher repetition rates (kHz), single-photon-sensitive detectors, shorter pulse widths, shorter normal point intervals for faster data acquisition, and increased pass interleaving, automated to autonomous operation with remote access, and embedded software for real-time updates and decision making. An example of pass interleaving is presented for the Yarragadee station (see Fig. 4); tracking of LEO satellites is often accommodated during break in LEO and GNSS passes. New satellites arrays provide more compact targets and work continues on the development of lighter less expensive arrays for satellites and the moon. The service now provides operational ITRF products including daily/ weekly station positions and daily resolution Earth orientation products; the flow of weekly combination of satellite orbit files for LAGEOS/Etalon-1 and -2 has recently been established. New products are under testing through a pilot project on systematic error monitoring currently underway. The article will give an overview of activities underway within the service, paths forward presently envisioned, and current issues and challenges.

Laser retroreflectors↗

DOE OSTI2024

Atmospheric clearing of solid-particle debris using femtosecond filaments

Through nonlinear self-focusing, femtosecond pulses can propagate several kilometers beyond diffraction limits, forming an ionization channel in air known as a laser filaments. It has been demonstrated that in the wake of the filament, aerosols can be effectively cleared to improve the transmission of subsequent laser pulses or secondary light sources, pertinent to applications in atmospheric sensing. However, the current understanding of aerosol clearing is founded on interactions with droplets to simulate fogs and clouds and thus does not extend to solid particles or atmospheric debris. Using optical trapping, we isolate both graphite and silica microparticles and directly measure the subsequent displacement caused by the filament using time-resolved shadowgraphy. The shock wave from the filament is demonstrated to propel particles away from the filament, directly contributing to atmospheric debris clearing. Particles exposed to the laser light in either the intense filament core or the surrounding energy reservoir are axially displaced along the beam path. Furthermore, it is found that the optomechanical properties of the particle largely influence the axial displacement induced by laser exposure through mechanisms such as radiation pressure, mass ejection from ablation or optical damage, and particle deagglomeration.

42 ENGINEERING↗

DOE OSTI2022

Strong laser polarization control of coherent phonon excitation in van der Waals material Fe 3 GeTe 2

Optical manipulation of coherent phonon frequency in two-dimensional (2D) materials could advance the development of ultrafast phononics in atomic-thin platforms. However, conventional approaches for such control are limited to doping, strain, structural or thermal engineering. Here, we report the experimental observation of strong laser-polarization control of coherent phonon frequency through time-resolved pump-probe spectroscopic study of van der Waals (vdW) materials Fe 3 GeTe 2 . When the polarization of the pumping laser with tilted incidence is swept between in-plane and out-of-plane orientations, the frequencies of excited phonons can be monotonically tuned by as large as 3% (~100 GHz). Our first-principles calculations suggest the strong planar and vertical inter-atomic interaction asymmetry in layered materials accounts for the observed polarization-dependent phonon frequencies, as in-plane/out-of-plane polarization modifies the restoring force of the lattice vibration differently. Our work provides insightful understanding of the coherent phonon dynamics in layered vdW materials and opens up new avenues to optically manipulating coherent phonons.

36 MATERIALS SCIENCE↗

NASA NTRS1984

Airborne laser topographic mapping results

The results of terrain mapping experiments utilizing the National Aeronautics and Space Administration (NASA) Airborne Oceanographic Lidar (AOL) over forested areas are presented. The flight tests were conducted as part of a joint NASA/U.S. Army Corps of Engineers (CE) investigation aimed at evaluating the potential of an airborne laser ranging system to provide cross-sectional topographic data on flood plains that are difficult and expensive to survey using conventional techniques. The data described in this paper were obtained in the Wolf River Basin located near Memphis, TN. Results from surveys conducted under winter 'leaves off' and summer 'leaves on' conditions, aspects of day and night operation, and data obtained from decidous and coniferous tree types are compared. Data processing techniques are reviewed. Conclusions relative to accuracy and present limitations of the AOL, and airborne lidar systems in general, to terrain mapping over forested areas are discussed.

Krabill, W. B.↗

DOE OSTI2022

Through the Lens of a Momentum Microscope: Viewing Light-Induced Quantum Phenomena in 2D Materials

Van der Waals (vdW) materials at their 2D limit are diverse, flexible, and unique laboratories to study fundamental quantum phenomena and their future applications. Their novel properties rely on their pronounced Coulomb interactions, variety of crystal symmetries and spin-physics, and the ease of incorporation of different vdW materials to form sophisticated heterostructures. In particular, the excited state properties of many 2D semiconductors and semi-metals are relevant for their technological applications, particularly those that can be induced by light. In this paper, the recent advances made in studying out-of-equilibrium, light-induced, phenomena in these materials are reviewed using powerful, surface-sensitive, time-resolved photoemission-based techniques, with a particular emphasis on the emerging multi-dimensional photoemission spectroscopy technique of time-resolved momentum microscopy. The advances this technique has enabled in studying the nature and dynamics of occupied excited states in these materials are discussed. Then, the future research directions opened by these scientific and instrumental advancements are projected for studying the physics of 2D materials and the opportunities to engineer their band-structure and band-topology by laser fields.

2D materials↗

NASA NTRS2007

Promoting Robust Design of Diode Lasers for Space: A National Initiative

The Diode-laser Array Working Group (DAWG) is a national-level consumer/provider forum for discussion of engineering and manufacturing issues which influence the reliability and survivability of high-power broad-area laser diode devices in space, with an emphasis on laser diode arrays (LDAs) for optical pumping of solid-state laser media. The goals of the group are to formulate and validate standardized test and qualification protocols, operational control recommendations, and consensus manufacturing and certification standards. The group is using reliability and lifetime data collected by laser diode manufacturers and the user community to develop a set of standardized guidelines for specifying and qualifying laser diodes for long-duration operation in space, the ultimate goal being to promote an informed U.S. Government investment and procurement strategy for assuring the availability and durability of space-qualified LDAs. The group is also working to establish effective implementation of statistical design techniques at the supplier design, development, and manufacturing levels to help reduce product performance variability and improve product reliability for diodes employed in space applications

Tratt, David M.↗

DOE OSTI2025

Mechanical and Thermal Characterization of Additively Manufactured Carbon/Nylon 12 and Carbon/PEEK Composites

This study explores additive manufacturing of carbon fiber-reinforced thermoplastic composites using the Composite-Based Additive Manufacturing (CBAM) process. Carbon/Nylon 12 and Carbon/PEEK composites were fabricated and evaluated through mechanical (compression, tensile, flexural, and impact) and thermal (DSC and TGA) tests. Carbon/PEEK exhibited superior mechanical performance, with 97.5% higher tensile strength, 79.8% higher elastic modulus, and 59.6% higher flexural strength compared to Carbon/Nylon 12. Thermal testing showed that Carbon/PEEK had higher thermal stability, beginning degradation at 350 °C versus 298 °C for Carbon/Nylon. These results indicate that CBAM-fabricated Carbon/PEEK composites are suitable for applications requiring high strength and temperature resistance.

Additive manufacturing↗

DOE OSTI2025

Time-Dependent 600 °C Post-Weld Heat Treatment Response of Laser-Wire-Directed Energy Deposited Austenitic Stainless Steel Claddings on Carbon Steel

Austenitic stainless steel overlay claddings are often used to protect nuclear reactor pressure vessels from corrosion. Arc welding processes are traditionally employed, which require a high heat input to bond the dissimilar metals, creating a large heat-affected zone and high residual stress that demands a lengthy stress-relieving post-weld heat treatment, up to 48 hours. High energy beam (e.g., laser, electron beam) directed energy deposition-based overlay cladding processes show promise for fabricating claddings with superior performance compared to arc welded ones because of their localized heat input; however, their necessity and time of post-weld heat treatment are currently unclear. In this research, we investigate the time dependence of a 600 C stress-relieving post-weld heat treatment of austenitic stainless steel clad on low carbon steel by laser-wire-directed energy deposition, comparing the microstructure and mechanical properties of the as-fabricated condition to 2-, 10-, and 48-hour heat treatment times. Diffusion simulations and microscopy show a gradual carburization of the stainless steel cladding and decarburization of the heat-affected zone/base metal. Nanoindentation testing shows up to a 1.8–2.69 embrittlement in the cladding and a 0.33 to 0.69 softening in the heat-affected zone after the 48-hour post-weld heat treatment. Tensile testing of the cladding composites reveals that increasing post-weld heat treatment time raises clad cracking susceptibility due to intergranular carbide formation and shows that laser-wire-directed energy deposition claddings may not require post-weld heat treatment.

Coating↗

DOE OSTI2023

Cladding and Butt-Joining Dissimilar Aluminum Alloys Simultaneously via Shear Assisted Processing and Extrusion

Shear assisted processing and extrusion has been used to fabricate multi-metallic tubing that incorporates regions with clad and butt-joined structures. In this work, aluminum alloys 6061, 7075, and 1100 are combined to create a monolithic extruded tubing with weldable ends (6061), a high strength center (7075), and a corrosion-resistant cladding (1100). Optical microscopy shows a gradual, defect-free, transition between alloys at the butt-joint interfaces and a sharp transition between alloys at the clad interface. Tensile testing proved the mechanical coherency of the joint, with failure occurring outside the tri-metallic structure. In conclusion, smoothed particle hydrodynamic simulations identified a spiral pattern of the cladding alloy that leads to inconsistent cladding thickness, and identified a simplified 2-alloy combination of aluminum alloys 6082 and 2014 that accomplished the design objectives of the tri-metallic structure.

Coatings↗

DOE OSTI2020

Engineering Directionality in Quantum Dot Shell Lasing Using Plasmonic Lattices

In this paper, we report how the direction of quantum dot (QD) lasing can be engineered by exploiting high-symmetry points in plasmonic nanoparticle (NP) lattices. The nanolaser architecture consists of CdSe-CdS core-shell QD layers conformally coated on two-dimensional square arrays of Ag NPs. Using waveguide-surface lattice resonances (W-SLRs) near the Δ point in the Brillouin zone as optical feedback, we achieved lasing from the gain in CdS shells at off-normal emission angles. Changing the periodicity of the plasmonic lattices enables other high-symmetry points (Γ or M) of the lattice to overlap with the QD shell emission, which facilitates tuning of the lasing direction. We also increased the thickness of the QD layer to introduce higher order W-SLR modes with additional avoided crossings in the band structure, which expands the selection of cavity modes for any desired lasing emission angle.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

DOE OSTI2025

Floquet–Bloch manipulation of the Dirac gap in a topological antiferromagnet

Floquet–Bloch manipulation, achieved by driving a material periodically with a laser pulse, is a method that enables the engineering of electronic and magnetic phases in solids by effectively modifying the structure of their electronic bands. However, the application of Floquet–Bloch manipulation in topological magnetic systems, particularly those with inherent disorder, remains largely unexplored. Here, in this study, we realize Floquet–Bloch manipulation of the Dirac surface-state mass of the topological antiferromagnet MnBi 2 Te 4 . Using time- and angle-resolved photoemission spectroscopy, we show that opposite helicities of mid-infrared circularly polarized light result in substantially different Dirac mass gaps in the antiferromagnetic phase, despite the equilibrium Dirac cone being massless. We explain our findings in terms of a Dirac fermion with a random mass. Our results underscore Floquet–Bloch manipulation as a powerful tool for controlling topology, even in the presence of disorder, and for uncovering properties of materials that may elude conventional probes.

42 ENGINEERING↗

DOE OSTI2020

Shock recompaction of spall damage

Spall fracture is a high strain-rate damage phenomenon associated with shock or impulsive loading events. When a material that has been subjected to shock compression is allowed to release, rarefaction waves propagate into the sample and reduce the internal stress to zero. If multiple rarefaction waves intersect, they generate tension which, if sufficient, can nucleate voids in the material. It has been observed in several works investigating spall fracture that although the shock-wave profiles suggested spall occurred, imaging of the recovered sample revealed no voids or cracks. In this study, we aim to determine whether a second shock event could recompact existing spall damage, and if so, what form does the microstructure at the recompaction interface have? Through a series of gas-gun flyer-plate impact experiments, we demonstrate that modest shock stresses of 2 GPa–3 GPa are enough to both fully compact a damaged copper target back to a state of zero porosity and, furthermore, drive recrystallization of the interface such that there is a new bond formed where the free surfaces were brought together.

42 ENGINEERING↗