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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

ICME and In-Situ Process Monitoring for Rapid Qualification of Components Made by Laser-based Powder Bed Additive Manufacturing Processes for Nuclear Structural Applications

Additive manufacturing (AM) through selective powder bed melting of successive layers is being considered as disruptive technology for rapid production of low-cost nuclear reactor internal components with complex geometries. However, there is a potential for non-uniform distribution of physical features, such as porosity or microstructural differences, due to variations of temperature across a component build. These heterogenities make the deployment of traditional material qualification and non-destructive evaluation of AM components difficult. This research project explored the feasibility of using in-situ process monitoring methods and integrated computational materials engineering (ICME) principles as an alternate qualification methodology and approach. This project included six individual tasks: (i) design of artifacts relevant to the nuclear power industry, (ii) evaluation of laser processing and in-situ measurements, (iii) computational modeling, (iv) ex-situ microstructural characterization, (v) evaluation of scaling the methodology for large-scale structures, and (vi) development of a data package to codes and standards organizations. As a part of this research, laser powder bed fusion of metals (316L, Alloy 718, and Ti6Al4V) was explored. This document provides an overview of the research performed over three years and serves as the final U.S. Department of Energy report for this project. In the third year, the project focused on the following activities: (a) in-situ infrared and optical imaging of each layer during processing of representative stainless steel geometries; (b) development of methodologies to analyze the data; and (c) application of ICME methodologies and other experiments to estimate the relevance of defects and microstructure to tensile properties.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2020

ICME and In-Situ Process Monitoring for Rapid Qualification of Components Made by Laser-based Powder Bed Additive Manufacturing Processes for Nuclear Structural Applications

Additive manufacturing (AM) through selective powder bed melting of successive layers is being considered as disruptive technology for rapid production of low-cost nuclear reactor internal components with complex geometries. However, there is a potential for non-uniform distribution of physical features, such as porosity or microstructural differences, due to variations of temperature across a component build. These heterogenities make the deployment of traditional material qualification and non-destructive evaluation of AM components difficult. This research project explored the feasibility of using in-situ process monitoring methods and integrated computational materials engineering (ICME) principles as an alternate qualification methodology and approach. This project included six individual tasks: (i) design of artifacts relevant to the nuclear power industry, (ii) evaluation of laser processing and in-situ measurements, (iii) computational modeling, (iv) ex-situ microstructural characterization, (v) evaluation of scaling the methodology for large-scale structures, and (vi) development of a data package to codes and standards organizations. As a part of this research, laser powder bed fusion of metals (316L, Alloy 718, and Ti6Al4V) was explored. This document provides an overview of the research performed over three years and serves as the final U.S. Department of Energy report for this project. In the third year, the project focused on the following activities: (a) in-situ infrared and optical imaging of each layer during processing of representative stainless steel geometries; (b) development of methodologies to analyze the data; and (c) application of ICME methodologies and other experiments to estimate the relevance of defects and microstructure to tensile properties.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2020

Non-destructive simulation of node defects in additively manufactured lattice structures

Additive Manufacturing (AM), commonly referred to as 3D printing, offers the ability to not only fabricate geometrically complex lattice structures but parts in which lattice topologies in-fill volumes bounded by complex surface geometries. However, current AM processes produce defects on the strut and node elements which make up the lattice structure. This creates an inherent difference between the as-designed and as-fabricated geometries, which negatively affects predictions (via numerical simulation) of the lattice’s mechanical performance. Although experimental and numerical analysis of an AM lattice’s bulk structure, unit cell and struts have been performed, there exists almost no research data on the mechanical response of the individual as-manufactured lattice node elements. Here we propose a methodology that, for the first time, allows non-destructive quantification of the mechanical response of node elements within an as-manufactured lattice structure. A custom-developed tool is used to extract and classify each individual node geometry from micro-computed tomography scans of an AM fabricated lattice. Voxel-based finite element meshes are generated for numerical simulation and the mechanical response distribution is compared to that of the idealised computer-aided design model. The method demonstrates compatibility with Uncertainty Quantification methods that provide opportunities for efficient prediction of a population of nodal responses from sampled data. Overall, the non-destructive and automated nature of the node extraction and response evaluation is promising for its application in qualification and certification of additively manufactured lattice structures.

36 MATERIALS SCIENCE↗
NASA NTRS1995

NASA Tech Briefs, June 1995

Topics include: communications technology, electronic components and circuits, electronic systems, physical sciences, materials, computer programs, mechanics, machinery, manufacturing/fabrication, mathematics and information sciences, life sciences, books and reports, a special section of laser Tech Briefs.

Source record↗
NASA NTRS1995

NASA Tech Briefs, December 1995

Topics include: a special focus section on Bio/Medical technology, electronic components and circuits, electronic systems, physical sciences, materials, computer programs, mechanics, machinery, manufacturing/fabrication, mathematics and information sciences, book and reports, and a special section on Laser Tech Briefs.

Source record↗
NASA NTRS1995

NASA Tech Briefs, August 1995

There is a special focus on computer graphics and simulation in this issue. Topics covered include : Electronic Components and Circuits; Electronic Systems; Physical Sciences; Materials; Computer programs, Mechanics; Machinery; Fabrication Technology; and Mathematics and Information Sciences. There is a section on for Laser Technology, which includes a feature on Moving closer to the suns power.

Source record↗
DOE OSTI2023

Investigation of the significance of excited species in wave-heated dense non-ideal microplasmas using particle-in-cell Monte Carlo-collision modeling

A computational model for the interaction of a high-pressure microplasma with an electromagnetic wave is presented. A one-dimensional particle-in-cell Monte Carlo collision model is used to investigate the plasma non-ideality effects in a second-stage laser-heated xenon plasma with a comprehensive chemistry mechanism, including excited species. A xenon microplasma at a temperature of 300 K and pressure of 10 bar becomes non-ideal after the laser heating stage with lower ionization and electronic excitation barriers, which makes the presence of excited species important to the plasma generation process. For these conditions, two-step ionization via excited species becomes a major contributor to plasma ionization. We find that full ionization of the plasma is obtained in ~2 ps when excited species are included in the chemistry model, as opposed to ~2.5 ps for a chemistry mechanism that does not consider their effect. With excited species, the ionization mode transitions from direct ionization via electron-neutral collisions to direct and stepwise ionization as the plasma generation progresses.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Experiments and simulations of isochorically heated warm dense carbon foam at the Texas Petawatt Laser

An experimental and simulation study of warm dense carbon foams at ambient density (n e ~10 21 cm –3 ) is presented. This study of isochorically heated foams is motivated by their potential application in carbon-atmosphere white-dwarf envelopes, where there are modeling uncertainties due to the equation of state. The foams are heated on an approximately picosecond time scale with a laser-accelerated proton beam. The cooling and expansion of the heated foams can be modeled with appropriately initialized radiation-hydrodynamics codes; xRAGE code is used in this work. The primary experimental diagnostic is the streaked optical pyrometer, which images a narrow band of radiation from the rear surface of the heated material. Presented are xRAGE modeling results for both solid aluminum targets and carbonized resorcinol-formaldehyde foam targets, showing that the foam appears to cool slowly on the pyrometer because of partial transparency. So that simulations of cooling foam are processed properly, it is necessary to account for finite optical depth in the photosphere calculation, and the methods for performing that calculation are presented in depth.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Effect of macroscopic surface defects on dynamic damage: An experimental and numerical study

This study examines the impact of macroscopic surface defects on the dynamic ductile damage behavior of polycrystalline metals using plate-impact experiments. Defects of various shapes (flat, round, and point) were manufactured on the free or impact surfaces of annealed copper specimens. The experiments were diagnosed with photon Doppler velocimetry measurements and soft recovery techniques. The experimental results revealed that defect shape and location significantly affect velocity–time profiles and void distribution. In order to understand the dynamics of shock propagation and corresponding ductile damage evolution within the target specimens, the impact experiments were modeled with a calibrated Tepla model, a dynamic ductile damage model for polycrystalline metals [Nguyen et al., Int. J. Solids Struct. 329, 113833 (2026)]. Overall, our resulting simulated velocity showed good agreement with measured velocity, and our simulated porosity distributions qualitatively matched experimental data. Based on our simulation results, defects on the free surface were found to distort rarefaction waves and therefore the corresponding spall planes. On the other hand, defects on the impact surface generated a delayed shock when the flyer plate and the defected target area were in contact, leading to distortion of the spall plane. The distortion of the spall plane resulted in a non-uniform distribution of voids within the defected specimens. Lastly, we examined the role of local work hardening due to the defect manufacturing process on the velocity and porosity distribution, using Tepla simulations with a simplified representation of local hardening. This investigation highlights the importance of defect geometry, location, and local hardening associated with defect generation in dynamic ductile damage processes.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Direct imaging of shock wave splitting in diamond at Mbar pressure

Understanding the behavior of matter at extreme pressures of the order of a megabar (Mbar) is essential to gain insight into various physical phenomena at macroscales—the formation of planets, young stars, and the cores of super-Earths, and at microscales—damage to ceramic materials and high-pressure plastic transformation and phase transitions in solids. Under dynamic compression of solids up to Mbar pressures, even a solid with high strength exhibits plastic properties, causing the induced shock wave to split in two: an elastic precursor and a plastic shock wave. This phenomenon is described by theoretical models based on indirect measurements of material response. The advent of x-ray free-electron lasers (XFELs) has made it possible to use their ultrashort pulses for direct observations of the propagation of shock waves in solid materials by the method of phase-contrast radiography. However, there is still a lack of comprehensive data for verification of theoretical models of different solids. Here, we present the results of an experiment in which the evolution of the coupled elastic–plastic wave structure in diamond was directly observed and studied with submicrometer spatial resolution, using the unique capabilities of the x-ray free-electron laser (XFEL). The direct measurements allowed, for the first time, the fitting and validation of the 2D failure model for diamond in the range of several Mbar. Our experimental approach opens new possibilities for the direct verification and construction of equations of state of matter in the ultra-high-stress range, which are relevant to solving a variety of problems in high-energy-density physics.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Enabling real-time adaptation of machine learning models at x-ray Free Electron Laser facilities with high-speed training optimized computational hardware

The emergence of novel computational hardware is enabling a new paradigm for rapid machine learning model training. For the Department of Energy’s major research facilities, this developing technology will enable a highly adaptive approach to experimental sciences. In this manuscript we present the per-epoch and end-to-end training times for an example of a streaming diagnostic that is planned for the upcoming high-repetition rate x-ray Free Electron Laser, the Linac Coherent Light Source-II. We explore the parameter space of batch size and data parallel training across multiple Graphics Processing Units and Reconfigurable Dataflow Units. We show the landscape of training times with a goal of full model retraining in under 15 min. Although a full from scratch retraining of a model may not be required in all cases, we nevertheless present an example of the application of emerging computational hardware for adapting machine learning models to changing environments in real-time, during streaming data acquisition, at the rates expected for the data fire hoses of accelerator-based user facilities.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2020

Sensitivity of Thermal Predictions to Uncertain Surface Tension Data in Laser Additive Manufacturing

To understand the process-microstructure relationships in additive manufacturing (AM), it is necessary to predict the solidification characteristics in the melt pool. This study investigates the influence of Marangoni driven fluid flow on the predicted melt pool geometry and solidification conditions using a continuum finite volume model. A calibrated laser absorptivity was determined by comparing the model predictions (neglecting fluid flow) against melt pool dimensions obtained from single laser melt experiments on a nickel super alloy 625 (IN625) plate. Using this calibrated efficiency, predicted melt pool geometries agree well with experiments across a range of process conditions. When fluid mechanics is considered, a surface tension gradient recommended for IN625 tends to overpredict the influence of convective heat transfer, but the use of an intermediate value reported from experimental measurements of a similar nickel super alloy produces excellent experimental agreement. Despite its significant effect on the melt pool geometry predictions, fluid flow was found to have a small effect on the predicted solidification conditions compared to processing conditions. We find that this result suggests that under certain circumstances, a model only considering conductive heat transfer is sufficient for approximating process-microstructure relationships in laser AM. Extending the model to multiple laser passes further showed that fluid flow also has a small effect on the solidification conditions compared to the transient variations in the process. Furthermore, limitations of the current model and areas of improvement, including uncertainties associated with the phenomenological model inputs are discussed.

36 MATERIALS SCIENCE↗
NASA NTRS2013

Comparison of Mars Science Laboratory Reaction Control System Jet Computations With Flow Visualization and Velocimetry

Numerical predictions of the Mars Science Laboratory reaction control system jets interacting with a Mach 10 hypersonic flow are compared to experimental nitric oxide planar laser-induced fluorescence data. The steady Reynolds Averaged Navier Stokes equations using the Baldwin-Barth one-equation turbulence model were solved using the OVERFLOW code. The experimental fluorescence data used for comparison consists of qualitative two-dimensional visualization images, qualitative reconstructed three-dimensional flow structures, and quantitative two-dimensional distributions of streamwise velocity. Through modeling of the fluorescence signal equation, computational flow images were produced and directly compared to the qualitative fluorescence data.

Bathel, Brett F.↗
NASA NTRS1993

LASER Tech Briefs, September 1993

This edition of LASER Tech briefs contains a feature on photonics. The other topics include: Electronic Components and Circuits. Electronic Systems, Physical Sciences, Materials, Computer Programs, Mechanics, Machinery, Fabrication Technology, Mathematics and Information Sciences, Life Sciences and books and reports.

Schnirring, Bill↗
DOE OSTI2026

Roadmap for warm dense matter physics

This roadmap presents the state-of-the-art, current challenges and near future developments anticipated in the thriving field of warm dense matter (WDM) physics. Originating from strongly coupled plasma physics, high pressure physics and high energy density science, the WDM physics community has recently taken a giant leap forward. This is due to spectacular developments in laser technology, diagnostic capabilities, and computer simulation techniques. Only in the last decade has it become possible to perform accurate enough simulations & experiments to truly verify theoretical results as well as to reliably design experiments based on predictions. Consequently, this roadmap discusses recent developments of and contemporary challenges for theoretical methods and experimental techniques needed to describe, create and diagnose WDM. A large part of this roadmap is dedicated to specific WDM systems and applications in astrophysics, inertial confinement fusion and novel material synthesis.

dense astrophysical objects↗
DOE OSTI2022

X-ray Computed Tomography as a Metrology Technique for the Analysis of Additively Manufactured Material

X-ray computed tomography (X-ray CT) is an analytical technique used in materials science to non-destructively characterize features in a variety materials like polymer, metals, composites, and explosives. It also has the capability of imaging additively manufacture, machine and assembled parts. The non-destructive imaging allows for the analysis of features (voids and cracks), which give a fundamental understanding of the material characteristics. Additionally, X-ray CT can obtain accurate measurements of dimensional and topographic variations due to different stimuli and assess the accuracy of material production. This study focuses on parts manufactured via metal additive manufacturing (AM). Although AM produces parts faster and easier, the printing process can produce defects (pores and surface roughness) that undermine the part’s mechanical properties and performance. The analysis of 3D printed objects has an asset in that the material has an STL file from which the item was printed, which is not available in many manufactured materials (i.e., foams) due to stochastic structures. For this study, the print accuracy of four additively manufactured cylinders will be assessed via X-ray CTto approximate the surface roughness and visualize any major morphological changes to assess the dimensional accuracy of complex additively manufactured parts. It was concluded that using X-ray CT to measure surface roughness was affective because reasonable surface roughness values were measured. Additionally, itwas determined that small-scale features can be produced via additive manufacturing with strong dimensional accuracy so long as the features are highly complex with sharp grooves.

36 MATERIALS SCIENCE↗
NASA NTRS2012

Comparison of MSL RCS Jet Computations With Flow Visualization and Velocimetry

Numerical predictions of the Mars Science Laboratory (MSL) reaction control system (RCS) jets interacting with a Mach 10 hypersonic flow are compared to experimental nitric oxide (NO) planar laser-induced fluorescence (PLIF) data. The steady Reynolds Averaged Navier Stokes (RANS) equations using the Baldwin-Barth one-equation turbulence model were solved using the OVERFLOW code. The experimental PLIF data used for comparison consists of qualitative two-dimensional visualization images, qualitative reconstructed three-dimensional flow structures, and quantitative two-dimensional distributions of streamwise velocity. Through modeling of the PLIF signal equation, computational flow images (CFI) were produced and directly compared to the qualitative PLIF data. Post processing of the experimental and simulation data enabled the jet trajectory to be extracted for a more quantitative comparison. The two-dimensional velocity fields were reconstructed through interpolation of a series of single-component velocity profiles. Each distribution of single-component velocity was obtained using molecular tagging velocimetry (MTV). After validating the numerical model, the numerical solution was further examined to gain insight into hypersonic jet-in-crossflow interaction. Future NO-PLIF experiments are proposed based on this analysis.

Johansen, Craig T.↗