MAGIS-100 Laser Transport Vacuum Simulations and LED Atom Tracker
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Due to the growing popularity of laser powder bed fusion (LPBF) as a metal additive manufacturing technique, there is a strong need to be able to accurately predict build outcomes. Full fidelity simulations of this process are not feasible due to the vast range of length and time scales inherent to it. While part-scale codes for simulating residual stress and distortion have shown reasonable predictive capability, they often neglect many aspects of the process occurring over smaller length/time scales, and thus are unable to capture effects of process parameter adjustments or the behavior of fine features. One way of capturing aspects at more refined length scales is through the use of adaptive mesh refinement (AMR). AMR allows for the process to be simulated at scales approaching the physical spatial dimensions without drastically increasing the total degrees of freedom in the simulation. This manuscript describes the implementation of an AMR algorithm within a multiphysics, parallelized finite element code, and its application to the LPBF problem. In this work, part-scale examples are provided where the use of AMR has allowed for higher fidelity thermal and thermomechanical simulations, as compared to experimental measurements. Results from these higher resolution simulations show that while AMR is a necessary component for increased accuracy in a computationally efficient manner, other improvements are also necessary, including handling of the multiple time scales inherent to the problem and the need for improved AM-specific material models.
Recently, much effort has been dedicated to the improvement of models and modeling choices utilized in radiation hydrodynamic simulations of direct drive inertial confinement fusion experiments in an effort to improve their predictive capability. In this paper, we consider the choice in mesh for the simulation of the laser ablation of a direct-drive-like target and compare Lagrangian simulations with various mesh zoning choices with Eulerian simulations with fixed resolution in the laser energy deposition region. Using these simulations, we demonstrate how errors in ablation pressure, laser deposition rate, shock speed, and density profile arise from insufficient zoning following from the conservation of mass of Lagrangian zones. These considerations place stringent requirements on the initial t = 0 zoning in the solid density shell for simulations aiming at resolving the ablation and laser absorption region. However, with sufficiently fine zoning in the t = 0 shell, agreement with Eulerian simulations and analytic scaling laws can be recovered.
X-ray free electron laser (XFEL) sources coupled to high-power laser systems offer an avenue to study the structural dynamics of materials at extreme pressures and temperatures. The recent commissioning of the DiPOLE 100-X laser on the high energy density (HED) instrument at the European XFEL represents the state-of-the-art in combining x-ray diffraction with laser compression, allowing for compressed materials to be probed in unprecedented detail. Here, we report quantitative structural measurements of molten Sn compressed to 85(5) GPa and ~3500 K. The capabilities of the HED instrument enable liquid density measurements with an uncertainty of ~1% at conditions which are extremely challenging to reach via static compression methods. We discuss best practices for conducting liquid diffraction dynamic compression experiments and the necessary intensity corrections which allow for accurate quantitative analysis. We also provide a polyimide ablation pressure vs input laser energy for the DiPOLE 100-X drive laser which will serve future users of the HED instrument.
The response of the cross-beam energy transfer instability (CBET) to laser bandwidth is investigated through a combination of theory and simulation. Existing linear theory is generalized to treat broadband lasers, demonstrating that CBET is most effectively suppressed when the bandwidth exceeds the ion-acoustic wave (IAW) frequency. It is shown that for such bandwidths, reverse (seed to pump) transfer becomes possible, which reduces the net energy transfer rapidly as bandwidth is increased. The CBET gain exponent in this regime scales with bandwidth (Δω) as Δω−3 for Gaussian or Lorentzian laser spectra with different scalings possible for other spectra. Comparison of our theory with linearized fluid and particle-in-cell simulations, performed with the laser-plasma simulation environment (LPSE) and vector particle in cell (VPIC) codes, respectively, finds that the model is accurate in the absence of nonlinear processes. However, linear analysis also finds that the IAW energy density scales as Δω−1, implying that nonlinear effects may be more difficult to control than the CBET scaling would suggest. Indeed, nonlinear effects are found to be present in VPIC simulations with high-intensity lasers, despite minimal apparent CBET. Nonlinear processes in the VPIC cases include particle trapping, the two-ion wave decay, and ion wave self-focusing. In some high intensity VPIC cases, these effects lead to net energy transfer from seed to pump and increases to backscatter stimulated Brillouin scattering reflectivities. Finally, for a given bandwidth, we show that improved control of nonlinear processes can be achieved via smoothing by spectral dispersion.
We present simulations of Omega shock tube experiments designed to investigate hot electron preheat effects in 3D-printed, two-photon polymerization (2PP) plastic lattices. Preheat is inferred in the experiments from the expansion of a plastic witness disk embedded in the lattice. Using the Eulerian radiation-hydrodynamics code xRAGE, we model shock propagation and preheat from both radiative and hot electron energy sources to evaluate their relative impact. To simulate the transport of laser-generated hot electrons, the nonlocal electron heat transport model proposed by Schurtz, Nicolaï, and Busquet (SNB) is extended with a hot electron source term and an energy cascade algorithm. We explore how variations in ablator, lattice geometry, and laser drive affect the shock velocity and witness disk expansion. Simulations show that the inclusion of a 5 μm gold layer reduces shock pressure by 60% and shock speeds by 30%–40% but does not significantly reduce the hot electron preheat, and that different lattice geometries lead to enhanced shock velocities—up to 40% faster than in homogeneous foams. However, radiative and conductive preheat from classical mechanisms alone fail to match experiment. By including a hot electron source term, we reproduce experimental observables such as disk expansion rates and spatial radiographic features. We find that a hot electron population corresponding to 4%–8% of the incident laser energy with T hot = 50 keV produces expansion which agrees with the experimental data, suggesting hot electron preheat is the most plausible explanation.
MAGIS-100 is an experiment using atom interferometry on strontium atoms in a 100m vacuum chamber. The laser travels through a laser transport system (LTS) before going down the chamber. Two projects were completed over the course of the internship. One project was conducting vacuum simulations on the LTS to ensure it meets the experimental pressure requirement of 10-11 torr. This was done by characterizing the pressure profile with variations in pump size, pump spacing, and orifice size. The initial design of the LTS included one 30 L/s ion pump in the high vacuum (HV) region, a lens mount with holes of diameter 0.788”, and three 150 L/s ion pumps in the ultra-high vacuum (UHV) region. After adjusting these variables, it was concluded that the lens mount holes could be reduced to 0.200” in diameter and one 150 L/s ion pump in the UHV could be removed and still meet the experimental requirements. The other project was to design an LED atom tracker that shows the position of the strontium atoms in the 100m shaft. This will help with public outreach by allowing visitors to have a visual of the experiment. An Arduino Uno and Arduino Due were programmed using classical physics formulas to direct the RGB LED strips to flash in sync with the falling atoms. The requirements for powering and connecting the hardware were calculated and recommendations for scaling the system to 100m were made.
Hohlraums are hollow cylindrical cavities with high-Z material walls used to convert laser energy into uniform x-ray radiation drives for inertial confinement fusion capsule implosions and high energy density physics experiments. Credible computational modeling of hohlraums requires detailed modeling and coupling of laser physics, hydrodynamics, radiation transport, heat transport, and atomic physics. We report on improvements to Los Alamos National Laboratory's xRAGE radiation-hydrodynamics code in order to enable hohlraum modeling. xRAGE's Eulerian hydrodynamics and adaptive mesh refinement make it uniquely well suited to study the impacts of multiscale features in hohlraums. In order to provide confidence in this new modeling capability, we demonstrate xRAGE's ability to produce reasonable agreement with data from several benchmark hohlraum experiments. We also use xRAGE to perform integrated simulations of a recent layered high density carbon capsule implosion on the National Ignition Facility in order to evaluate the potential impacts of the capsule support tent, mixed cell conductivity methodologies, plasma transport, and cross-beam energy transfer (XBT). We find that XBT, seeded by plasma flows in the laser entrance hole (LEH), causes a slight decrease in energy coupling to the capsule and that all of these impact the symmetry of the x-ray drive such that they have an appreciable impact on the capsule implosion shape.
Critical to the creation of a multi-component SiC receiver design concept capable of meeting the SETO CST cost goal objectives of <$150/kWth is the optimal utilization of material for solar absorption and heat transfer to transport fluid. This is to maximize the solar-thermal efficiency in the techno-economic analysis of derived use case. As a first step in preparation of sub-component design for on-sun test evaluations we use different proposed SiC absorber element in a customized laser heat flux test to assess an effective heat transfer coefficient characteristic of the design. The test results are analyzed to extract the effective heat transfer coefficient, thus enable optimization of the geometry of receiver components for heat transfer, efficiency attributes and the thermo-structural management of the components. High intensity CO2 laser is used in combination with air flow through the test specimen to assess the effective heat transfer coefficient under heat flux conditions corresponding to high solar concentrations in the range of 1000-2000 suns.
In order to demonstrate acceleration of electrons to relativistic scales by an on chip dielectric laser accelerator (DLA), a ponderomotive focusing scheme capable of capturing and transporting electrons through nanometer-scale apertures over extended interaction lengths has been proposed. Here we present a Matlab-based numerical code (SHarD) utilizing a spatial harmonic expansion of the fields within the dielectric structure to simulate the evolution of the beam phase space distribution in this scheme. The code can be used to optimize key-parameters for the accelerator performance such as the final energy, transverse spot size evolution and total number of electrons accelerated through currently fabricated structures. Eventually, the simulation model will be applied to inform the phase mask profile to be added to a pulse front tilt drive laser pulse using a liquid crystal mask in the experimental setup being assembled at UCLA Pegasus Laboratory.
Here, we report the result of investigations into alternative representations of the temporal evolution of the laser powder bed fusion (LPBF) process. In order to provide the reader with sufficient context for the following discussion, the modeling challenge and its underlying cause, as well as current attempts to provide a satisfactory solution, will be discussed. Next, the author will describe two numerical methods (multirate time integration and parallel-in-time) to better represent the temporal scales of the problem. Finally, the results of applying these methods to a two-dimensional version of the heat transfer portion of the LPBF problem will be presented, reporting on both convergence and performance behavior, which indicate the possibility of significant speedup of solution calculations (40–100 times), along with well-characterized effects on solution accuracy.
Increasing operating temperatures of solar receivers is paramount to the efficiency of concentrated solar thermal (CST) and solar power (CSP) systems. Owing to its high temperature stability combined with excellent thermal and optical properties, SiC has been the material of choice for application in high-temperature solar receivers. We report the results of our study of the effective heat transfer characteristics of several candidate SiC structure motifs, or feature geometries, which are fabricated via additive manufacturing. The SiC structure motifs studied include different permutations of three-dimensional periodic lattices and defined shapes. A solar-thermal simulating laboratory test setup is constructed using a 4kW CO2 laser system with beam shaping optics to apply concurrent radiative heating power on one face of 2”-diameter cylindrical feature specimens, representing the structure motifs of interest for receiver element design, while flowing through the sample as heat transfer fluid. Using the test setup, simulative test conditions representative of a concentrated solar flux of up to ~2000 suns could be achieved in the lab tests under varying air flow through the test structure. A simple 1D numerical analysis scheme is developed to extract an effective or compound heat transfer coefficient representative of the test structure under steady-state heat flow conditions. The test results and their use to guide the selection and optimization of SiC material and structure motifs for the receiver element design fabrication are discussed.
The presentation reviews the progress made toward reducing the joining time of an advanced nickel-based alloy, Alloy 740H by a factor of two using a novel two step fusion welding approach. In the first step, a high powered laser is used to rapidly join thick weld groove lands (~10-12 mm thick) during a single pass. Hybrid laser arc welding (HLAW) is then used to fill the remaining weld groove and complete the joint. This sequential process also utilizes laser wobble in both steps to reduce welding defects and refine the weld microstructure to obtain improved properties compared to conventional gas tungsten or gas metal arc welds, GTAW and GMAW, respectively. The creep behavior of laser-only thick weld groove land welds and HLAW welds were found to be the same or slightly improved compared to conventional GMAW or GTAW welds in this alloy. Creep tests have been started to verify the long-term creep behavior (~10,000 hrs) of these welds. Modeling results on deep penetration laser welding are presented and the initial simulations of laser welding with laser wobble are shown. The next phase of the project will combine the two processes to make complete welds - deep penetration laser welds of thick weld groove lands followed by rapid filling of the remaining weld groove by HLAW - in thick plates (32 mm thick) Alloy 740H plate and entails development of narrow weld groove welding to further decrease the joining time of this alloy.
Recent experiments involving directly driven beryllium spheres are reported. Plasma conditions are measured using Thomson scattering with the probe beam pointed 200, 300, and 400 μ m from the surface of the sphere. Laser coupling is assessed using calorimeters that collect scattered light placed at various locations within the target chamber. Laser intensities of 1 0 14 W / c m 2 and 2.5 × 1 0 14 W / c m 2 are chosen to minimize unmodeled laser-plasma interactions (LPIs) that lead to laser-target decoupling. Two-dimensional simulations are compared to the interpreted data using the radiation-hydrodynamics code Lasnex. Heat transport is simulated using flux-limited Spitzer–Harm with both high ( f = 0.15) and low ( f = 0.03) flux limiters and the Schurtz–Nicolai-Busquet (SNB) model. At 1 0 14 W / c m 2 , all three heat transport models agree well with the measurement, demonstrating that the heat flux is local at low intensities near the measurement locations. At 2.5 × 1 0 14 W / c m 2 , the SNB and high flux model roughly match the plasma conditions but predict 2% uncoupled light compared to 10% measured. Additionally, the use of drive multipliers to match the measured coupled light does not alter the agreement between measured and simulated plasma conditions, suggesting that decoupling due to LPI is unlikely to alter this agreement. The low flux model cannot match the plasma conditions and results in 19% scattered light. The use of a resonant absorption model can be used to bring the simulated scattered light into agreement, but the simulated plasma conditions are still in disagreement with the measurement. For this reason, the low flux model is rejected.
Ramp-wave dynamic-compression experiments are used to examine quasi-isentropic loading paths in materials. The gradual and continuous increase in pressure created by ramp waves make these types of experiments ideal for studying nonequilibrium material behavior, such as solidification kinetics. In ramp-wave compression experiments, the input drive pressure to the experimental setup may be exerted through one of a number of different mechanisms (e.g., magnetic fields, gas-gun-driven impactors, or high-energy lasers) and is generally required for simulating such experiments. Yet, regardless of the specific mechanism, this drive pressure cannot be measured directly (measurements are generally taken at a location near the back of the experimental setup through a transparent window), leading to an inverse problem where one must determine the drive pressure at the front of the experimental setup (i.e., the input) that corresponds to the particle velocity (the output) measured near the back of the experimental setup. Furthermore, we solve this inverse problem using a heuristic optimization algorithm, known as differential evolution, coupled with a multiphysics, hydrodynamics code that simulates the compression of the experimental setup. By running many rounds of forward simulations of the experimental setup, our optimization process iteratively searches for a drive pressure that is optimized to closely reproduce the experimentally measured particle velocity near the back of the experimental setup. While our optimization methodology requires a significant number of hydrodynamics simulations to be conducted, many of these can be performed in parallel, which greatly reduces the time cost of our methodology. One novel aspect of our method for determining the drive pressure is that it does not require physical modeling of the drive mechanism and can thus be broadly applied to many types of ramp-compression experiments, regardless of the drive mechanism.