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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 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Data-driven prediction of geometry- and toolpath sequence-dependent intra-layer process conditions variations in laser powder bed fusion

Geometrical features and toolpath sequence are two important factors that cause process condition variations, such as variations in the meltpool temperature or meltpool size, that might lead to undesired material properties in the laser powder bed fusion (LPBF) process. Due to the high dynamics and complex physics of the LPBF process, it is difficult to predict variations in process conditions with simulations alone. Advances in measurement technology and computational technologies open up new possibilities for smart manufacturing. In this paper, a data-driven method to predict intra-layer variations in the processing conditions that source from the toolpath sequence and part geometry is presented. The approach is demonstrated using two-color on-axis pyrometer measurements. Three demonstration cases are presented in which it is demonstrated (1) how the trained predictive model can be used as a filter to ease the interpretation of process variations and discover patterns related to toolpath and part geometry, and (2) how to generate predictions that can be used for feedforward control, i.e., for adjusting laser power or scanning speed along the toolpath using a meltpool temperature prediction model generated based on on-axis measurements. Results show that the developed prediction model is able to meaningfully predict process variations resulted from toolpath sequence and geometry. Predictions are aligned with the results from the related work of others and for the case of 180° laser path turnarounds in our high-speed X-ray imaging experiments. In conclusion, the potential issues related to the current maturity status of the process and measuring equipment that could in practice affect the performance of the proposed solutions are also discussed.

42 ENGINEERING↗
DOE OSTI2023

Femtosecond Laser-Induced Nano-Joining of Volatile Tellurium Nanotube Memristor

Nanowire/nanotube memristor devices provide great potential for random-access high-density resistance storage. However, fabricating high-quality and stable memristors is still challenging. This paper reports multileveled resistance states of tellurium (Te) nanotube based on the clean-room free femtosecond laser nano-joining method. The temperature for the entire fabrication process was maintained below 190 °C. A femtosecond laser joining technique was used to form nanowire memristor units with enhanced properties. Femtosecond (fs) laser-irradiated silver-tellurium nanotube-silver structures resulted in plasmonic-enhanced optical joining with minimal local thermal effects. This produced a junction between the Te nanotube and the silver film substrate with enhanced electrical contacts. Noticeable changes in memristor behavior were observed after fs laser irradiation. Capacitor-coupled multilevel memristor behavior was observed. Compared to previous metal oxide nanowire-based memristors, the reported Te nanotube memristor system displayed a nearly two-order stronger current response. The research displays that the multileveled resistance state is rewritable with a negative bias.

42 ENGINEERING↗
DOE OSTI2025

Target fabrication fields first NIF shot with new 3D-printed microfluidic target design

Capable of producing ultrafine features, two-photon polymerization (2PP) 3D printing made it possible to field a first-of-its-kind leak-proof liquid-filled diffraction target. These targets are used for shots aimed at using laser pressure instead of low temperatures turn water into ice. The shot is the product of months of design, assembly, and installation work by LSEO’s target fabrication team, in collaboration with 3D printing experts Widi Moestopo (MED) and Xiaoxing Xia (MED) and PLS researcher Neal Bhandarkar.

42 ENGINEERING↗
DOE OSTI2021

A Bayesian Approach to the Eagar–Tsai Model for Melt Pool Geometry Prediction with Implications in Additive Manufacturing of Metals

Here, this paper focuses on improving the melt pool geometry predictions and quantifying uncertainties using an adapted version of the Eagar–Tsai (E–T) model that incorporates temperature-dependent properties of the material as well as powder conditions. Additionally, Bayesian inference is employed to predict distributions for the E–T model input parameters of laser absorptivity and powder bed porosity by incorporating experimental results into the analysis. Monte Carlo uncertainty propagation is then used with these parameter distributions to estimate the melt pool depth and associated uncertainty. Our results for the 316L stainless steel suggest that both the absorptivity and powder bed porosity are strongly influenced by the laser power. In contrast, the scanning speed has only a marginal effect on both the absorptivity and powder bed porosity. We constructed a printability map using the Bayesian E–T model based on power-dependent input parameter values to demonstrate the merit of the approach. The Bayesian approach improved the accuracy in predicting the keyhole regions in the laser power-scan speed parameter space for the 316L stainless steel. Although applied to a specific adaptation of the E–T model, the method put forth can be extended to quantify uncertainties in other numerical models as well as in the estimation of unknown parameters.

316L Stainless Steel (SS).↗
DOE OSTI2020

Elucidating the effect of preheating temperature on melt pool morphology variation in Inconel 718 laser powder bed fusion via simulation and experiment

In laser powder bed fusion (L-PBF) additive manufacturing, the mechanical performance, microstructure and defects of fabricated parts are closely associated with the melt pool morphology, e.g., its dimension and shape through the building process. Past studies have largely focused on how the process parameters such as laser power and scan speed affect melt pool characteristics. In this study, the melt pool morphology variation as a function of preheating temperature in the conduction, transition, and keyhole regimes and the underlying mechanisms in each regime are investigated through ex-situ sample characterization and computation thermal fluid dynamics (CtFD) simulation. Single tracks with different combinations of laser power and scan speed are deposited on an Inconel 718 bare plate preheated to a temperature range of 100–500 °C in the experiment. Significant changes are observed in melt pool morphology as a function of preheating temperature from optical measurements of melt track cross sections. The depth of melt pool in the three regimes increases monotonically with preheating temperature, e.g., at 500 °C, the experimental melt pool depth is increased by 49% in conduction regime, 34% in transition regime and 33% in keyhole regime, respectively, while the variation of melt pool width in each regime does not all follow an increasing trend but depends on the melt pool regimes. Melt pool width variation in the conduction and transition regimes is found to depend on the enhanced heat conduction directly related to temperature dependent thermal properties. Through validated CtFD simulations, it is found that in the keyhole regime the evaporation mass, recoil pressure, and laser drilling effect is enhanced with higher preheating temperature, which gives rise to a deeper melt pool. The simulations also reveal that preheating temperature significantly elongates the melt track length due to the increased flow rate and strong recoil pressure that accelerates the backward flow.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Melt pool temperature measurement and monitoring during laser powder bed fusion based additive manufacturing via single-camera two-wavelength imaging pyrometry (STWIP)

Melt pool (MP) temperature is one of the determining factors and a key signature for evaluating the properties of printed components in metal additive manufacturing (AM). The state-of-the-art measurement systems are hindered, primarily by the large-scale data acquisition and processing demands. In this work, we introduce a novel coaxial, high-speed, single-camera two-wavelength imaging pyrometer (STWIP) system as opposed to the typical utilization of multiple cameras for measuring MP temperature profiles in laser powder bed fusion (LPBF) processes. Developed on a commercial LPBF machine (EOS M290), the STWIP system demonstrated its ability to quantitatively monitor the MP temperature and its variation for 50 layers at high framerates (>30,000 fps) for a real-world application (standard fatigue specimens) print. High performance computing is employed to analyze the acquired big data (MP images), for determining each MP's average temperature and 2D temperature profile. The MP temperature evolution in the gage section of a fatigue specimen is also examined at a temporal resolution of 1 ms, by evaluating the MP temperatures in the samples' first, middle, and last layers. This report is the first of its kind on monitoring MP temperature distribution and evolution at such a large, detailed scale for longer durations in practical applications.

42 ENGINEERING↗
DOE OSTI2023

Phase Locking of a THz QC-VECSEL to a Microwave Reference

We report high-resolution frequency study and phase locking have been performed on a terahertz (THz) quantum-cascade vertical-external-cavity surface-emitting laser (QC-VECSEL) operating around 2.5 THz. A subharmonic diode mixer is used to down convert the THz signal to a 100 MHz intermediate frequency that is phase locked to a stable 100 MHz microwave reference. Between 90% and 95% of the QC-VECSEL signal is locked within 2 Hz of the multiplied RF reference, and amplitude fluctuations on the order of 1%–10% are observed, depending on the bias point of the QC-VECSEL. The bandwidth of the locking loop is ~1 MHz. Many noise peaks in the IF signal are observed, likely corresponding to mechanical resonances in the 10 Hz–10 kHz. These peaks are generally -30 to -60 dB below the main tone and are below the phase noise level of the multiplied RF reference that ultimately limits the phase noise of the locked QC-VECSEL.

42 ENGINEERING↗
DOE OSTI2022

A process optimization framework for laser direct energy deposition: Densification, microstructure, and mechanical properties of an Fe-Cr alloy

Laser Direct Energy Deposition (DED) is a metal additive manufacturing technique with the ability to fabricate large and complex parts through deposition of metal powders. However, achieving high-density parts and targeted build heights using DED can be challenging due to the large number of highly sensitive process variables. This work proposes a robust fabrication parameter optimization framework to generate process maps for primary parameters in DED, including laser power, scan speed, mass flow rate, hatch spacing, and layer height. Simple single-track experiments were utilized to map out the parameter space, and a combination of geometric criteria for hatch spacing and layer height were proposed to determine parameter sets that achieve both targeted build heights and mitigate porosity formation. Using this framework, specimens with >99 % density and consistent mechanical properties were successfully fabricated over a wide range of process parameters for an Fe-9wt.%Cr (Fe9Cr) alloy, a surrogate for radiation damage-resistant reduced activation ferritic/martensitic (RAFM) steels. Processing these materials using DED is of particular interest in the development of plasma facing components for nuclear fusion applications. The microstructure and mechanical properties of as-printed Fe9Cr were characterized using optical and electron microscopy, X-ray diffraction, and uniaxial tensile tests. As-printed Fe9Cr displayed ~25 % elongation and ultimate tensile strengths of up to 475 MPa which is comparable to similar wrought alloys. Finally, the proposed framework will allow for accelerated DED parameter optimization for novel alloy systems, as well as open the possibility for local microstructure control while simultaneously mitigating defect formation.

42 ENGINEERING↗
DOE OSTI2025

Optically Addressable Light Valve Based on a GaN:Mn Photoconductor

Semi-insulating manganese-doped gallium nitride (GaN:Mn) layers epitaxially grown on unintentionally doped GaN substrates were used as photoconductors in optically addressable light valves (OALVs) to withstand higher operational laser fluences compared to current state-of-the-art OALVs where bismuth silicon oxide (BSO; Bi 12 SiO 20 ) layers are used as photoconductors. GaN:Mn promises to be an exciting material for optoelectronic operations due to its large laser fluence handling capability and photoresponsivity near the band edge. The laser damage thresholds for the semi-insulating epitaxial GaN:Mn layer and the n-type substrate layer were measured to be 2.4 and 4.2 J/cm 2 , respectively. These are 6–10 times higher than that of BSO (0.4 J/cm 2 ). These measurements were performed by exposing ~200 sites on the samples to increasing fluence levels from a Gaussian pulsed Nd:YAG laser system (1064 nm) operating at a 5 Hz repetition rate with a 3 ns pulse width. Photoresponsivity of the GaN:Mn material was investigated at discrete wavelengths of 447, 405, and 380 nm. Further, the peak photoresponsivity was observed under an illumination wavelength of 380 nm and is attributed to stronger absorption. The OALV was fabricated by attaching a 110-μm-thick GaN:Mn layer grown on a 280-μm-thick n-GaN layer to a 3-mm-thick BK7 optical window. A twisted nematic E7 liquid crystal was introduced to the 5 μm gap between the two components. Transmission levels of >90% were achieved for the fabricated OALVs for a peak voltage of 40 V, constrained by transmission “bleed-through”.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Automated compatibility checking of prefabricated components using 3D as-built models and BIM

There have been recent efforts to use reality capture technologies to perform remote quality control in construction. However, there is a lack of research efforts in detecting construction incompatibilities in modular construction using reality capture technologies. The construction incompatibilities in modular construction often cause reworks and delays in the project schedule. To address this issue, this paper presents a general compatibility analysis method that propose scanning the modules in manufacturing plant and construction site, and check module-to-module compatibility remotely, prior to the shipment and installation. This study provides three sample module-to-module compatibility scenarios to validate the proposed compatibility analysis. The case study results show that the compatibility analysis method was able to identify the compatibility issues with high accuracy. Lastly, the compatibility analysis method was validated in terms of accuracy and time performance in six scenarios that was defined on the modules.

42 ENGINEERING↗
DOE OSTI2021

High-performance photonic transformers for DC voltage conversion

Abstract Direct current (DC) converters play an essential role in electronic circuits. Conventional high-efficiency DC voltage converters, especially step-up type, rely on switching operation, where energy is periodically stored within and released from inductors and/or capacitors connected in a variety of circuit topologies. Since these energy storage components, especially inductors, are fundamentally difficult to scale down, miniaturization of switching converters proves challenging. Furthermore, the resulting switching currents produce significant electromagnetic noise. To overcome the limitations of switching converters, photonic transformers, where voltage conversion is achieved through light emission and detection processes, have been demonstrated. However, the demonstrated efficiency is significantly below that of the switching converter. Here we perform a detailed balance analysis and show that with a monolithically integrated design that enables efficient photon transport, the photonic transformer can operate with a near-unity conversion efficiency and high voltage conversion ratio. We validate the theory with a transformer constructed with off-the-shelf discrete components. Our experiment showcases near noiseless operation and a voltage conversion ratio that is significantly higher than obtained in previous photonic transformers. Our findings point to the possibility of a high-performance optical solution to miniaturizing DC power converters and improving the electromagnetic compatibility and quality of electrical power.

42 ENGINEERING↗
DOE OSTI2022

Correlated color temperature is not a suitable proxy for the biological potency of light

Using a simulation based on a real, five-channel tunable LED lighting system, we show that Correlated Color Temperature (CCT) is not a reasonable predictor of the biological potency of light, whether characterized with CIE melanopic Equivalent Daylight Illuminance (mel-EDI), Equivalent Melanopic Lux (EML) (a scalar multiple of mel-EDI), or Circadian Stimulus (CS). At a photopic corneal illuminance of 300 lx and Rf ≥ 70, spectra can vary in CS from 17 to 41% across CCTs from 2500 to 6000 K, and up to 23% at a single CCT, due to the choice of spectrum alone. The CS range is largest, and notably discontinuous, at a CCT of 3500 K, the location of the inflection point of the CS model. At a photopic corneal illuminance of 300 lx and Rf ≥ 70, mel-EDI can vary from 123 to 354 lx across CCTs from 2500 to 6000 K and can vary by up to 123 lx at a fixed CCT (e.g., 196 to 319 lx at 5000 K). The range of achievable mel-EDI increases as CCT increases and, on average, decreases as color fidelity, characterized with IES TM-30 Rf, increases. These data demonstrate that there is no easy mathematical conversion between CS and mel-EDI when a spectrally diverse spectra set of spectral power distributions is considered.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2021

Observation of Hydrodynamic Flows in Imploding Fusion Plasmas on the National Ignition Facility [plus supplemental information]

Inertial confinement fusion implosions designed to have minimal fluid motion at peak compression often show significant linear flows in the laboratory, attributable per simulations to percent-level imbalances in the laser drive illumination symmetry. In this work, we present experimental results which intentionally varied the mode 1 drive imbalance by up to 4% to test hydrodynamic predictions of flows and the resultant imploded core asymmetries and performance, as measured by a combination of DT neutron spectroscopy and high-resolution x-ray core imaging. Neutron yields decrease by up to 50%, and anisotropic neutron Doppler broadening increases by 20%, in agreement with simulations. Furthermore, a tracer jet from the capsule fill-tube perturbation that is entrained by the hot-spot flow confirms the average flow speeds deduced from neutron spectroscopy.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

Improving Experimental Baseline Schedule Resiliency at the National Ignition Facility

The goal of this system is to provide a universal method of capturing and integrating campaign level target requirements for experiments at the National Ignition Facility (NIF) prior to establishing a baseline schedule. The expected outcome is a more resilient schedule able to accurately incorporate long lead target requirements.

42 ENGINEERING↗
DOE OSTI2021

Fiber optic system for direct detection of CO 2 leakage in carbon storage wells (Abbreviated Final Report)

The feasibility study focused on the development of new fiber for distributed chemical sensing that will allow direct detection of CO2 leakages in the environment. This is particularly important for monitoring well integrity for carbon capture and storage (CSS), which can provide early warning for an incoming well failure and potential CO2 leaking through it. We proposed Raman or IR interrogation within gas-filled Holey Fibers (HoFs) interleaved with Fiber Bragg Grating (FBG) sections, so that the location and concentration of the gases would be provided simultaneously. The methodology would overcome current roadblocks to using fiber optics for CO2 (and other gases) detection in wells with direct in-situ measurements of concentration along with other important parameters such as temperature and pressure. We were able to assess commercially available IR/Raman hollow core fiber and demonstrated detection of CO2 through them in our controlled environment setups at various pressure conditions. We have also established the ability of drilling precisely with fs-lases side holes to enable penetration of CO2 into the hollow core fiber and reduce diffusion rates. Open joint collars were also explored with double functionality: to obtain splice to solid core fiber critical for field deployment and create gas ingress locations. Both diffusion-only and pressurized fiber system have been constructed following COMSOL based semi-hybrid optical /fluidodynamics models. FBGs have been identified and procured and characterized. Along the work we leveraged internal modeling/design, photonics/laser characterization, optical fiber fabrication, and AM lab capabilities to design, develop and test in-house components or assemblies. Our results indicate the potential of HoF for CO2 downhole direct detection.

25 ENERGY STORAGE↗
DOE OSTI2024

BB Milestone Report (V.5)

This report represents fulfillment of the NIF milestone for Demonstration of the Feasibility for Mitigation of SBS Backscatter using Blue Blocker Optics. It summarizes work to date for evaluating the performance of the optic and the role this new blue blocker optic can play in NIF.

42 ENGINEERING↗