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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 OSTI2020

In situ/operando synchrotron x-ray studies of metal additive manufacturing

Additive manufacturing (AM) comprises a group of transformative technologies that are likely to revolutionize manufacturing. In particular, laser-based metal AM techniques can not only fabricate parts with extreme complexity, but also provide innovative means for designing and processing new metallic systems. However, there are still several technical barriers that constrain metal AM. Overcoming these barriers requires a better understanding of the physics underlying the complex and dynamic laser–metal interaction at the heart of many AM processes. Furthermore, this article briefly describes the state of the art of in situ/operando synchrotron x-ray imaging and diffraction for studying metal AM, mostly the laser powder-bed fusion process. It highlights the immediate impact of operando synchrotron studies on the advancement of AM technologies, and presents future research challenges and opportunities.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Variant selection in laser powder bed fusion of non-spherical Ti-6Al-4V powder

The presence of α/α' on prior β/β grain boundaries directly impacts the final mechanical properties of the titanium alloys. The β/β grain boundary variant selection of titanium alloys has been assumed to be unlikely owing to the high cooling rates in laser powder bed fusion (L-PBF). However, we hypothesize that powder characteristics such as morphology (non-spherical) and particle size (50–120 µm) could affect the initial variant selection in L-PBF processed Ti-6Al-4V alloy by locally altering the cooling rates. Despite the high cooling rate found in L-PBF, the results showed the presence of β/β grain boundary α' lath growth inside two adjacent prior β grains. Electron backscatter diffraction micrographs confirmed the presence of β/β grain boundary variant selection, and synchrotron X-ray high-speed imaging observation revealed the role of the “shadowing effect” on the locally decreased cooling rate because of keyhole depth reduction and the consequent β/β grain boundary α' lath growth. The self-accommodation mechanism was the main variant selection driving force, and the most abundant α/α boundary variant was type 4 (63.26°//[ $\bar{10}$ 5 5 $\bar{3}$ ]). The dominance of Category II α lath clusters associated with the type 4 α/α boundary variant was validated using the phenomenological theory of martensite transformations and analytical calculations, from which the stress needed for the β→α' transformation was calculated.

36 MATERIALS SCIENCE↗
NASA NTRS1999

Quantitative Interferometry in the Severe Acoustic Environment of Resonant Supersonic Jets

Understanding fundamental fluidic dynamic and acoustic processes in high-speed jets requires quantitative velocity, density and temperature measurements. In this paper we demonstrate a new, robust Liquid Crystal Point Diffraction Interferometer (LCPDI) that includes phase stepping and can provide accurate data even in the presence of intense acoustic fields. This novel common path interferometer (LCPDI) was developed to overcome difficulties with the Mach Zehnder interferometer in vibratory environments and is applied here to the case of a supersonic shock- containing jet. The environmentally insensitive LCPDI that is easy to align and capable of measuring optical wavefronts with high accuracy is briefly described, then integrated line of sight density data from the LCPDI for two underexpanded jets are presented.

Mercer, Carolyn R.↗
DOE OSTI2024

Effects of Aluminum Plate Initial Residual Stress on Machined-Part Distortion

Dimensional tolerances for high-speed-machined aluminum products continue to tighten due to the demand for automated assembly of complex monolithic parts in aerospace and other industries. Understanding the contribution of inherent residual stress in wrought Al 7050-T7451 plate, common in aircraft manufacture, to distortion of high-aspect-ratio machined parts is critical but remains problematic due to the alloy's low residual stress magnitude over large geometries. Prior investigations into residual stress effects on machined part distortion suffer inadequate characterizations of the wrought material stress field, either because of low fidelity due to “slitting” methods, confounding effects in machined-layer removal methods, or small sample size when using neutron diffraction (ND). In this work, inherent residual stress is measured via ND at 860 locations in a 90.5 mm thick Al 7050-T7451 plate having dimensions 399 mm in the rolling direction and 335 mm in the transverse direction. Unlike prior studies, the ND residual stress is reconstructed using an iterative algorithm to ensure fully compatible, equilibrated 3D field prior to examining its effect on distortion. Further, the findings from simulations and experiments show that inherent residual stress alone could distort a high-aspect-ratio part beyond aerospace industry requirements, that slitting measurements may not sufficiently characterize residual stress for predicted distortion, and that parts machined from different plate thickness locations could exhibit reversed distortion patterns. Thus, research into distortion prediction that considers machining should carefully characterize and reconstruct inherent residual stress so that the coupled machining effects are accurately modeled.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Ultrafast all-optical diffraction switching using semiconductor metasurfaces

Ultrafast all-optical switching using Mie resonant metasurfaces requires both on-demand tunability of the wavefront of the light and ultrafast time response. However, devising a switching mechanism that has a high contrast between its “on” and “off” states without compromising speed is challenging. Here, we report the design of a tunable Mie resonant metasurface that achieves this behavior. Our approach utilizes a diffractive array of semiconductor resonators that support both dipolar and quadrupolar Mie resonances. By balancing the strengths of the dipole and quadrupole resonances, we can suppress radiation into the first diffraction order, thus creating a clearly delineated “off”-state at the operating wavelength. Then, we use optical injection of free- carriers to spectrally shift the multipoles and rebalance the multipole strengths, thereby enabling radiation into the diffraction order—all on an ultrafast timescale. We demonstrate ultrafast off-to-on switching with I on /I off ≈ 5 modulation of the diffracted intensity and ultrafast on-to-off switching with Ion/Ioff ≈ 9 modulation. Furthermore, both switches exhibit a fast τ tr ≈ 2.7 ps relaxation time at 215 μJ cm -2 pump fluence. Further, we show that for higher fluences, the temporal response of the metasurface is governed by thermo-optic effects. This combination of multipole engineering with lattice diffraction opens design pathways for tunable metasurface-based integrated devices.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2026

Additively manufactured high-entropy alloy mimics the pressure-induced structural transition of iron

We report a pressure-induced structural phase transformation in an additively manufactured (AM) AlCrFe 2 Ni 2 high-entropy alloy. High laser scan-speed processing during AM has been shown to strongly suppress FCC formation, yielding BCC/B2-dominant microstructures. Synchrotron x-ray diffraction reveals a reversible BCC/B2 → HCP transition near ∼13 GPa that mirrors the α-Fe → ɛ-Fe transformation in elemental iron. Notably, this iron-like phase change occurs despite substantial chemical disorder and multi-element site occupancy, demonstrating that the BCC lattice instability leading to close-packed polymorphs can persist in a highly disordered matrix. At ambient pressure, AlCrFe 2 Ni 2 exhibits robust ferromagnetic behavior associated with the BCC/B2 phase. The observation of an α-Fe–like polymorphic pathway in a chemically complex alloy shows that classic cubic-to-close-packed transformation physics is not extinguished by compositional complexity. As a result, AlCrFe 2 Ni 2 emerges as a model system for exploring pressure-driven polymorphism and potential magneto-structural coupling in high-entropy alloys.

36 MATERIALS SCIENCE↗
NASA NTRS2013

Miniaturized, High-Speed, Modulated X-Ray Source

A low-cost, miniature x-ray source has been developed that can be modulated in intensity from completely off to full intensity on nanosecond timescales. This modulated x-ray source (MXS) has no filaments and is extremely rugged. The energy level of the MXS is adjustable from 0 to more than 100 keV. It can be used as the core of many new devices, providing the first practical, arbitrarily time-variable source of x-rays. The high-speed switching capability and miniature size make possible many new technologies including x-ray-based communication, compact time-resolved x-ray diffraction, novel x-ray fluorescence instruments, and low- and precise-dose medical x-rays. To make x-rays, the usual method is to accelerate electrons into a target material held at a high potential. When the electrons stop in the target, x-rays are produced with a spectrum that is a function of the target material and the energy to which the electrons are accelerated. Most commonly, the electrons come from a hot filament. In the MXS, the electrons start off as optically driven photoelectrons. The modulation of the x-rays is then tied to the modulation of the light that drives the photoelectron source. Much of the recent development has consisted of creating a photoelectrically-driven electron source that is robust, low in cost, and offers high intensity. For robustness, metal photocathodes were adopted, including aluminum and magnesium. Ultraviolet light from 255- to 350-nm LEDs (light emitting diodes) stimulated the photoemissions from these photocathodes with an efficiency that is maximized at the low-wavelength end (255 nm) to a value of roughly 10(exp -4). The MXS units now have much higher brightness, are much smaller, and are made using a number of commercially available components, making them extremely inexpensive. In the latest MXS design, UV efficiency is addressed by using a high-gain electron multiplier. The photocathode is vapor-deposited onto the input cone of a Burle Magnum(TradeMark) multiplier. This system yields an extremely robust photon-driven electron source that can tolerate long, weeks or more, exposure to air with negligible degradation. The package is also small. When combined with the electron target, necessary vacuum fittings, and supporting components (but not including LED electronics or high-voltage sources), the entire modulated x-ray source weighs as little as 158 grams.

Gendreau, Keith↗
NASA NTRS1994

Control of unsteady separated flow associated with the dynamic stall of airfoils

A unique active flow-control device is proposed for the control of unsteady separated flow associated with the dynamic stall of airfoils. The device is an adaptive-geometry leading-edge which will allow controlled, dynamic modification of the leading-edge profile of an airfoil while the airfoil is executing an angle-of-attack pitch-up maneuver. A carbon-fiber composite skin has been bench tested, and a wind tunnel model is under construction. A baseline parameter study of compressible dynamic stall was performed for flow over an NACA 0012 airfoil. Parameters included Mach number, pitch rate, pitch history, and boundary layer tripping. Dynamic stall data were recorded via point-diffraction interferometry and the interferograms were analyzed with in-house developed image processing software. A new high-speed phase-locked photographic image recording system was developed for real-time documentation of dynamic stall.

Wilder, M. C.↗
NASA NTRS1995

The use of cowl camber and taper to reduce rotor/stator interaction noise

The project had two specific technical objectives: (1) to develop a realistic three-dimensional model of tonal noise due to rotor/stator interaction, as the input field for predictions of diffraction and dissipation by a lined cowl; and (2) to determine whether the generator curve of that cowl, or duct, could be 'steered' to yield substantially lower values of propulsor noise along the engine's fore and aft open sectors. The more general and important aim of their research is to provide the commercial aircraft industry with a useful predictive tool to help it meet its noise-reduction goals. The work has produced a tractable and yet realistic model of rotor/stator interaction noise. The blades in the fan stage are radially divergent, twisted, and of realistically wide chords to match the high frequencies and speeds of the sound-production process. The resulting three-dimensional acoustic nearfield insonifies the interior wall of the diffracting cowl, whose shape, incidentally, does not affect fore or aft noise significantly (but other factors do).

Martinez, R.↗
NASA NTRS2019

Microstructural and Mechanical Characterization of a Dispersion Strengthened Medium Entropy Alloy Produced Using Selective Laser Melting

High entropy alloys (HEAs) are an interesting new class of alloys which have been shown to exhibit both notable strength and ductility for a wide range of temperature and stresses. In addition, the remarkably small difference between the solvus and liquidus temperatures for many face centered cubic HEAs makes them an excellent candidate for selective laser melting fabrication. In this study, the microstructure and mechanical properties of a dispersion strengthened equiatomic NiCoCr alloy successfully produced using selective laser melting are explored. The effect laser speed, laser power, and powder recyclability have on final part density and microstructural segregation are analyzed through both x-ray diffraction and high resolution scanning electron microscopy. These results are further validated and compared to stable phase predictions produced using a commercially available high entropy alloy mobility database. Lastly, the tensile strengths resulting from different heat treatment pathways are detailed.

Smith, T. M.↗
DOE OSTI2026

Grayscale projection two-photon lithography using sub-diffraction motifs for ultrafast and precise nanoscale 3D printing

Rapid and high-fidelity nanoscale 3D printing is highly desirable, but it is difficult due to the tradeoff between speed and accuracy. Although optical projection techniques can massively scale up printing, fidelity is compromised due to the difficulty in precisely controlling the light dosage over the entire field. This challenge is typically addressed by using multiple projections, but it slows down printing. Here, we present grayscale projection two-photon lithography to overcome this tradeoff. Despite using a binary mask, it enables projecting more than 15,000 focal spots, each with independently tunable intensity. It advantageously leverages constraints imposed by optical diffraction to achieve grayscale tuning over the entire field at once. By directly tuning the focal spot intensities, we demonstrate suppression of proximity effects, compensation of non-uniform illumination, compensation of stitching artefacts, and rapid 3D printing with a single femtosecond pulse per layer. We demonstrate printing of nanowires as thin as 55 nm and achieve rates of 1.7 billion voxels/s and 215 mm 3 /hr.

36 MATERIALS SCIENCE↗
DOE OSTI2023

A High-Speed Rotational Diamond Anvil Cell for In Situ Analysis of Hierarchical Microstructural Evolution of Metallic Alloys during Extreme Shear Deformation

High speed shear deformation is ubiquitous in engineering applications, ranging from material processing methods such as friction stir processing/extrusion and in tribological contacts. However, analyzing the microstructural evolution of materials while they are undergoing high speed shear deformation have been a long-standing challenge. This led to predominant reliance on ex situ microscopy before and after shear deformation. But ex situ microscopy lacks the ability to analyze dynamic and transient hierarchical microstructural evolution mechanisms that could occur during shear deformation of materials. Therefore, to better understand the dynamic mechanisms of mass and energy transfer in materials under shear deformation, we developed a first of its kind high-speed rotational diamond anvil cell (HS-RDAC) for synchrotron-based in situ high-energy x-ray diffraction (XRD). We studied the time resolved lattice strain evolution, XRD peak broadening and changes in spatial variation of shear deformation induced alloying in pure metal and metal alloy sheets and powder mixture using the HS-RDAC. These in situ results were combined with detailed ex situ microstructural characterization before and after the shear deformation using transmission electron microscopy and atom probe tomography, which revealed the different stages of evolution of a shear deformation induced hierarchical nanostructure. Multiscale computational simulations including computational fluid dynamics, crystal plasticity, molecular dynamic simulation and density functional theory uncovered the mechanisms behind morphological changes, evolution of defect structures and changes in driving force for shear deformation induced intermixing. In conclusion, this in situ HS-RDAC capability, in combination with ex situ microstructural characterization and computational simulations, can provide new insights into the hierarchical microstructural evolution pathway during shear deformation.

36 MATERIALS SCIENCE↗
NASA NTRS2008

Instrument Performance of GISMO, a 2 Millimeter TES Bolometer Camera used at the IRAM 30 m Telescope

In November of 2007 we demonstrated a monolithic Backshort-Under-Grid (BUG) 8x16 array in the field using our 2 mm wavelength imager GISMO (Goddard IRAM Superconducting 2 Millimeter Observer) at the IRAM 30 m telescope in Spain for astronomical observations. The 2 mm spectral range provides a unique terrestrial window enabling ground-based observations of the earliest active dusty galaxies in the universe and thereby allowing a better constraint on the star formation rate in these objects. The optical design incorporates a 100 mm diameter silicon lens cooled to 4 K, which provides the required fast beam yielding 0.9 lambda/D pixels. With this spatial sampling, GISMO will be very efficient at detecting sources serendipitously in large sky surveys, while the capability for diffraction limited imaging is preserved. The camera provides significantly greater detection sensitivity and mapping speed at this wavelength than has previously been possible. The instrument will fill in the spectral energy distribution of high redshift galaxies at the Rayleigh-Jeans part of the dust emission spectrum, even at the highest redshifts. Here1 will we present early results from our observing run with the first fielded BUG bolometer array. We have developed key technologies to enable highly versatile, kilopixel, infrared through millimeter wavelength bolometer arrays. The Backshort-Under-Grid (BUG) array consists of three components: 1) a transition-edge-sensor (TES) based bolometer array with background-limited sensitivity and high filling factor, 2) a quarter-wave reflective backshort grid providing high optical efficiency, and 3) a superconducting bump-bonded large format Superconducting Quantum Interference Device (SQUID) multiplexer readout. The array is described in more detail elsewhere (Allen et al., this conference). In November of 2007 we demonstrated a monolithic 8x 16 array with 2 mm-pitch detectors in the field using our 2 mm wavelength imager GISMO (Goddard IRAM Superconducting 2 Millimeter Observer) at the IRAM 30 m telescope in Spain for astronomical observations. The 2 mm spectral range provides a unique terrestrial window enabling ground-based observations of the earliest active dusty galaxies in the universe and thereby allowing a better constraint on the star formation rate in these objects. The optical design incorporates a 100 mm diameter silicon lens cooled to 4 K, which provides the required fast beam yielding 0.9 lambda1D pixels. With this spatial sampling, GISMO will be very efficient at detecting sources serendipitously in large sky surveys, while the capability for diffraction limited imaging is preserved. The camera provides significantly greater detection sensitivity and mapping speed at this wavelength than has previously been possible. The instrument will fill in the spectral energy distribution of high redshift galaxies at the Rayleigh-Jeans part of the dust emission spectrum, even at the highest redshifts. Here I will we present early results from our observing run with the first fielded BUG bolometer array.

Staguhn, Johannes↗
NASA NTRS2007

GISMO

The 2 mm (1 50 GHz) atmospheric window enables unparalleled ground-based observations of the earliest active dusty galaxies in the universe. We have undertaken the development of a bolometer camera, GISMO (the Goddard-IRAM Superconducting 2-Millimeter Observer), which will obtain large and sensitive sky maps at this wavelength. The instrument will be used at the IRAM 30 m telescope, where we hope to have a trial observing run in Spring of 2007. The innovative element in this camera is its 8x1 6 fully sampled planar array of multiplexed superconducting transition edge sensor bolometers. This array is based on our recently demonstrated Backshort Under Grid architecture, designed to be scaled to kilopixel arrays with high sensitivity (of around 4 * 10 (exp -17)/ W* square root of Hz at T(sub c) approximates 450mK). A compact cryogenic optical system provides a wide field of view, (almost 2'x4') enabling GISMO to be very efficient at detecting sources serendipitously in large sky surveys, while retaining diffraction-limited imaging performance. GISMO will provide significantly greater imaging sensitivity and mapping speed at this wavelength than has previously been possible. The major scientific driver for the instrument is to detect dust emission from high-z Ultraluminous Infrared Galaxies (ULIRGs) and quasars. The instrument provides an important portion of the spectrum of high redshift galaxies at the Rayleigh-Jeans part of the dust emission spectrum, even at the highest redshifts. Models of galaxy evolution predict that GISMO will serendipitously detect one galaxy in every four hours of observing blank sky, and that one quarter of these galaxies will be at a redshift of z > 6.5.

Benford, Dominic↗
NASA NTRS1993

Fabricating binary optics: An overview of binary optics process technology

A review of binary optics processing technology is presented. Pattern replication techniques have been optimized to generate high-quality efficient microoptics in visible and infrared materials. High resolution optical photolithography and precision alignment is used to fabricate maximally efficient fused silica diffractive microlenses at lambda = 633 nm. The degradation in optical efficiency of four-phase-level fused silica microlenses resulting from an intentional 0.35 micron translational error has been systematically measured as a function of lens speed (F/2 - F/60). Novel processes necessary for high sag refractive IR microoptics arrays, including deep anisotropic Si-etching, planarization of deep topography and multilayer resist techniques, are described. Initial results are presented for monolithic integration of photonic and microoptic systems.

Stern, Margaret B.↗
NASA NTRS1989

A 58 x 62 pixel Si:Ga array camera for 5 - 14 micron astronomical imaging

A new infrared array camera system has been successfully applied to high background 5 - 14 micron astronomical imaging photometry observations, using a hybrid 58 x 62 pixel Si:Ga array detector. The off-axis reflective optical design incorporating a parabolic camera mirror, circular variable filter wheel, and cold aperture stop produces diffraction-limited images with negligible spatial distortion and minimum thermal background loading. The camera electronic system architecture is divided into three subsystems: (1) high-speed analog front end, including 2-channel preamp module, array address timing generator, bias power suppies, (2) two 16 bit, 3 microsec per conversion A/D converters interfaced to an arithmetic array processor, and (3) an LSI 11/73 camera control and data analysis computer. The background-limited observational noise performance of the camera at the NASA/IRTF telescope is NEFD (1 sigma) = 0.05 Jy/pixel min exp 1/2.

Gezari, D. Y.↗
NASA NTRS1994

A Phase Locked High Speed Real-Time Interferometry System for Large Amplitude Unsteady Flows

A high speed phase locked interferometry system has been designed and developed for real-time measurements of the dynamic stall flow over a pitching airfoil. Point diffraction interferograms of incipient flow separation over a sinusoidally oscillating airfoil have been obtained at rates of up to 20 KHz and for free stream Mach numbers of 0.3 and 0.45. The images were recorded on ASA 125 and ASA 400 film using a drum camera. Special electronic timing and synchronizing circuits were developed to trigger the laser light source from the camera, and to initiate acquisition of the interferogram sequence from any desired phase angle of oscillation. The airfoil instantaneous angle of attack data provided by an optical encoder was recorded via a FIFO and in EPROM into a microcomputer. The interferograms have been analyzed using software developed in-house to get quantitative flow density and pressure distributions.

Chandrasekhara, M. S.↗
NASA NTRS1982

Highly versatile computer-controlled television detector system

A description is presented of a television detector system which has been designed to accommodate a wide range of applications. It is currently being developed for use in X-ray diffraction, X-ray astrophysics, and electron microscopy, but it is also well suited for astronomical observations. The image can be integrated in a large, high-speed memory system, in the memory of a computer system, or the target of the TV tube or CCD array. The detector system consists of a continuously scanned, intensified SIT vidicon with scan and processing electronics which generate a digital image that is integrated in the detector memory. Attention is given to details regarding the camera system, scan control and image processing electronics, the memory system, and aspects of detector performance.

Kalata, K.↗