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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 541 records · Page 30
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

A Gaussian Process-Based extended Goldak heat source model for finite element simulation of laser powder bed fusion additive manufacturing process

In this study, laser powder bed fusion (L-PBF) additive manufacturing (AM) is a key enabling technology to manufacture highly complex and integrated metallic structures. In L-PBF AM process, the melting of the metal powders and the layers underneath can be governed by either “conduction mode” or “keyhole mode”, with the keyhole mode reportedly leading to porosity and decreased strength and ductility by many studies. In part scale simulations, finite element (FE) model is often used to study the temperature distribution during printing and to predict the residual stress, where a volumetric heat flux with a Gaussian or a double ellipsoidal (Goldak) distribution is often applied as the laser heat source. However, the above heat source models can only capture the melt pool shape in the conduction mode, and fail to capture the transition to keyhole melting mode when the process parameters change. To overcome this inaccuracy, an extended Goldak heat source model is proposed by introducing a laser penetration term as a function of laser parameters obtained from a Gaussian-Process (GP) model. The model is validated by “2D pad” AlSi10Mg L-PBF experiments under a wide range of laser power, scan speed, and laser focus offset, and the results show the model successfully captures the measured melt pool shape in all conditions.

36 MATERIALS SCIENCE↗
DOE OSTI2023

High precision control of laser energy for laser–matter interaction studies

Precise, highly reproducible control of the laser energy is required for high confidence laser–matter interaction research such as in dynamic compression science and high energy density physics. The energy must be adjustable without affecting the pulse shape (time varying intensity) or beam smoothness. We have developed a convenient two-stage energy tuning method for a nominal 100 J, 351 nm (UV) laser. The energy is adjusted in 10 J (10%) increments by operating the laser at full energy and inserting a beam splitter in the laser output. As the splitter is located after the final frequency tripling optics, the UV pulse shape is unchanged. The energy is varied by substituting a splitter of different reflectivity. For finer 3 J (3%) increments, the infrared pulse is attenuated inside the laser before the final amplifier. This requires modest tuning to preserve the pulse shape. The demonstrated variation in shot-to-shot reproducibility is less than +/–2.5 J (5% of the full energy), irrespective of the laser output energy. These approaches can be adapted to most ~100 J class lasers. We describe these techniques and show two examples where they have elucidated the underlying physics in laser shock compression experiments. One used only the beam splitters to establish the pressure for melting in iron. The other combined both techniques to finely increment the peak stress (~2 GPa steps) in germanium to precisely determine the onset and completion of melting—including the melting kinetics. Furthermore, these unambiguous results would not be possible without the developments described here.

47 OTHER INSTRUMENTATION↗
DOE OSTI2022

Development of a Laser Ultrasonics-based Approach for Rapid Screening of High Entropy Alloys

This project utilized a laser ultrasonic technique to systematically study temperature-induced evolution of material properties in a set of interrelated binary alloys and a high entropy alloy (HEA) fabricated using arc-melting and spark plasma sintering processes. This technique involved the use of a nanosecond duration, high-intensity pulsed laser to thermo-elastically generate ultrasonic waves that propagate in the bulk of the metal alloy. Sub-nanometer-scale displacements associated with the propagating bulk ultrasonic waves were detected along the epicenter on the opposite surface of the sample using a 1 GHz bandwidth photorefractive interferometer. Phase transformations and microstructural changes were inferred from the temperature-dependent trends in the bulk acoustic velocities and features in the ultrasonic epicentral waveforms measured in the binary alloys. These inferences were then correlated with electron/optical microscopy observations and predictions using calculations of phase diagrams (CALPHAD). The results showed that the laser-generated ultrasonic pulses were strongly influenced by changes in material microstructure and could accurately track thermally driven phase transformations and detect the presence of microscale heterogeneities (grain boundaries, dendritic structures, etc.) in the set of binary alloy samples. The measurement approach was then applied to a quinary HEA sample for estimating phase transition temperature and determining microstructural heterogeneity. The rapid, non-contact and non-destructive ultrasonic testing approach demonstrated here is amenable to high throughput combinatorial investigations that can be applied to graded composition HEAs produced using advanced manufacturing methods. When paired with atomistic simulations and CALPHAD modeling, this approach can overcome the bottlenecks faced by current material characterization methods in efficiently screening the vast discovery space of HEAs that spans over a hundred million unique quinary alloy compositions.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Site‐selective fluorescence and spectroscopic properties of Yb‐doped lanthanum titanate glasses

Abstract Ytterbium‐doped lanthanum titanate glasses were prepared by levitation melting for the detailed characterization of the spectroscopic properties in the rare‐earth titanate glass host. Low‐temperature fluorescence spectroscopy reveals distinct site‐selectivity in both static and lifetime fluorescence measurements suggesting an absence of clustering as well as significant variation of local ytterbium environments. Typical site‐selectivity behavior of a shrinking Stark manifold with lower excitation energy is observed. At 77 K, both the mean emission frequency and the fluorescence lifetime initially increase as the excitation energy decreases from about 11100 to 10750 and then slightly decrease at lower excitation energy. Temperature‐dependent lifetime measurements between 77 and 420 K show a decreasing lifetime with increasing temperature and are well described by a two‐level thermal activation model. The temperature‐dependent fluorescence spectroscopy coupled with a room temperature white light absorption measurement allow the determination of the Stark energy levels of in lanthanum titanate glass as well as the calculation of the laser cross‐sections.

Materials Science↗
NASA NTRS1984

A redetermination of the succinonitrile-water phase diagram

The phase diagram of the water/succinonitrile system often used in modeling binary metallic alloys is determined experimentally using a laser scattering method. Triply distilled and zone-refined succinonitrile is placed in a jacketed water-cooled vessel with a magnetic mixer and a copper-constantan thermocouple, and the melting point is determined under vacuum and under Ar by observing the response of a photodiode placed opposite a laser source as the chamber is cooled and reheated. Then water is added, and the eutectic and monotectic temperatures and the entire phase diagram are determined under Ar. The results are presented in a table and graph and compared to those of Schreinemakers (1897): significant discrepancies are noted and attributed to impurities in the succinonitrile used by Schreinemakers. The importance of accurate phase diagrams for modeling binary alloys is stressed.

Smith, J. E., Jr.↗
DOE OSTI2025

A high-throughput approach for statistical process optimization in Laser Powder Bed Fusion

Process variability is inherent in metal additive manufacturing (AM). However, it is often overlooked in process optimization frameworks, constraining the understanding of process uncertainties and their influence on parameter selection. To address this, we present an integrated framework that combines high-throughput single-track experiments, GAN-based melt pool geometry extraction, robust statistical and machine learning modeling, and uncertainty-quantified process mapping. Process variability is characterized through single-track melt pool behaviors, and its influence on defect formation is systematically quantified to enable statistically guided process parameter optimization. This approach is demonstrated on Laser Powder Bed Fusion (L-PBF) of stainless steel 316L, effectively capturing the interplay between process parameters, melt pool variability, and defect probability. By integrating uncertainty quantification into process optimization, this study provides a structured methodology for addressing variability challenges in AM quality control, ultimately contributing to enhanced manufacturing reliability.

Laser Powder Bed Fusion↗
NASA NTRS2014

Identification of Martian Regolith Sulfur Components in Shergottites Using Sulfur K Xanes and Fe/S Ratios

Based on isotopic anomalies in Kr and Sm, Sr-isotopes, S-isotopes, XANES results on S-speciation, Fe/S ratios in sulfide immiscible melts [5], and major element correlations with S determined in impact glasses in EET79001 Lith A & Lith B and Tissint, we have provided very strong evidence for the occurrence of a Martian regolith component in some impact melt glasses in shergottites. Using REE measurements by LA-ICP-MS in shergottite impact glasses, Barrat and co-workers have recently reported conflicting conclusions about the occurrence of Martian regolith components: (a) Positive evidence was reported for a Tissint impact melt, but (b) Negative evidence for impact melt in EET79001 and another impact melt in Tissint. Here, we address some specific issues related to sulfur speciation and their relevance to identifying Martian regolith components in impact glasses in EET79001 and Tissint using sulfur K XANES and Fe/S ratios in sulfide immiscible melts. XANES and FE-SEM measurements in approx. 5 micron size individual sulfur blebs in EET79001 and Tissint glasses are carried out by us using sub-micron size beams, whereas Barrat and coworkers used approx. 90 micron size laser spots for LA- ICP-MS to determine REE abundances in bulk samples of the impact melt glasses. We contend that Martian regolith components in some shergottite impact glasses are present locally, and that studying impact melts in various shergottites can give evidence both for and against regolith components because of sample heterogeneity.

Sutton, S. R.↗
NASA NTRS2008

Tetravalent chromium doped laser materials and NIR tunable lasers

A method is described to improve and produce purer Cr.sup.4+-doped laser materials and lasers with reduced co-incorporation of chromium in any other valence states, such as Cr.sup.3+, Cr.sup.2+, Cr.sup.5+, and Cr.sup.6+. The method includes: 1) certain crystals of olivine structure with large cation (Ca) in octahedral sites such as Cr.sup.4+:Ca.sub.2GeO.sub.4, Cr.sup.4+:Ca.sub.2SiO.sub.4, Cr.sup.4+:Ca.sub.2Ge.sub.xSi.sub.1-xO.sub.4 (where 0<x<1), and/or 2) high-temperature solution growth techniques that enable the growth of the crystals below the temperature of polymorphic transitions by using low melting point solvent based on oxide, fluoride and/or chloride compounds. Purer Cr.sup.4+-doped laser materials are characterized by a relatively high concentration of Cr.sup.4+-lasing ion in crystalline host that makes these materials suitable for compact high power (thin disk/wedge) NIR laser applications.

Alfano, Robert R.↗
DOE OSTI2025

Nanoscale interfacial melting enables bonding during high velocity microparticle impacts

Melting during high-velocity particle impact has been understood to be typically detrimental to bonding by lowering the strength at the interface and promoting rebound before solidification can occur. Here we establish a possible remedy to this challenge: by dramatically restricting the volume of molten material, its resolidification is accelerated, effectively forming a nanoscale, braze-type joint during impact. In-situ single particle impact imaging is combined with post-mortem structural and chemical analyses to reveal a regime where adhesion is governed not by extensive plastic deformation, but by the kinetics of melt layer resolidification. Furthermore, these findings redefine the role of melting in impact-based processes, establishing transient melting and rapid solidification as a viable strategy for engineering successful adhesion events.

Additive manufacturing↗
DOE OSTI2020

The origin and formation of oxygen inclusions in austenitic stainless steels manufactured by laser powder bed fusion

The origins of nano-scale oxide inclusions in 316L austenitic stainless steel (SS) manufactured by laser powder bed fusion (L-PBF) was investigated by quantifying the possible intrusion pathways of oxygen contained in the precursor powder, extraneous oxygen from the process environment during laser processing, and moisture contamination during powder handling and storage. When processing the fresh, as-received powder in a wellcontrolled environment, the oxide inclusions contained in the precursor powder were the primary contributors to the formation of nano-scale oxides in the final additive manufactured (AM) product. These oxide inclusions were found to be enriched with oxygen getter elements like Si and Mn. By controlling the extraneous oxygen level in the process environment, the oxygen level in AM produced parts was found to increase with the extraneous oxygen level. The intrusion pathway of this extra oxygen was found to be dominated by the incorporation of spatter particles into the build during processing. Moisture induced oxidation during powder storage was also found to result in a higher oxide density in the AM produced parts. SS 316L powder free of Si and Mn oxygen getters was processed in a well-controlled environment and resulted in a similar level of oxygen intrusion. Finally, microhardness testing indicated that the oxide volume fraction increase from extraneous oxygen did not influence hardness values. However, a marked decrease in hardness was found for the humidified and Si-Mn free AM processed parts.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Ultrafast laser-induced spin–lattice dynamics in the van der Waals antiferromagnet CoPS 3

CoPS 3 stands out in the family of the van der Waals antiferromagnets XPS 3 (X = Mn, Ni, Fe, and Co) due to the unquenched orbital momentum of the magnetic Co 2+ ions, which is known to facilitate the coupling of spins to both electromagnetic waves and lattice vibrations. Here, using a time-resolved magneto-optical pump–probe technique, we experimentally study the ultrafast laser-induced dynamics of mutually correlated spins and lattice. It is shown that a femtosecond laser pulse acts as an ultrafast heater and, thus, results in the melting of the antiferromagnetic order. At the same time, the resonant pumping of the 4 T 1g → 4 T 2g electronic transition in Co 2+ ions effectively changes their orbital momentum, giving rise to a mechanical force that moves the ions in the direction parallel to the orientation of their spins, thus generating a coherent B g phonon mode at the frequency of about 4.7 THz.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
NASA NTRS2012

Depth and Differentiation of the Orientale Melt Lake

Impact melt emplacement and evolution in lunar multi-ring basins is poorly understood since impact melt deposits in basins are generally buried by mare basalt fill and obscured by subsequent impact cratering. The relatively young Orientale basin, which is only partially flooded with mare basalt, opens a rare window into basin-scale impact melts. We describe the geology of impact melt-related facies in Orientale and suggest that the central depression of Orientale may represent a solidified impact melt lake that vertically subsided shortly after basin formation due to solidification and cooling. We use Lunar Orbiter Laser Altimeter (LOLA) data to measure the depth (approx. 1.75 km) and diameter (approx 350 km) of this central depression. If all the observed subsidence of the central depression is due to solidification and cooling, the melt lake should be approx 12.5-16 km deep, far more voluminous (approx 106 km3) than the largest known differentiated igneous intrusions on Earth. We investigate the possibility that the Orientale melt lake has differentiated and model 1) the bulk composition of the melt lake, 2) the operation of melt mixing in the melt lake, and 3) the chemical evolution of the resulting liquids on the An-Fo-Qz ternary in order to predict the lithologies that might be present in the solidified Orientale melt lake. Finally, we consider the possible significance of these lithologies.

Vaughan, W. M.↗
DOE OSTI2023

Corrosion testing needs and considerations for additively manufactured materials in nuclear reactors

Metal additive manufacturing holds significant promise as an enabling technology for the 21st century nuclear energy industry. Metal additive manufacturing (MAM) can allow the fabrication of novel materials and innovative component designs that are not achievable through conventional manufacturing. Due to its very different fabrication methods, as-fabricated MAM components are characteristically different from conventionally manufactured components. MAM materials exhibit very different microstructures from conventional cast or wrought materials. For example, austenitic stainless steels fabricated by laser powder bed fusion exhibit columnar grain structures, dislocation cell structures, and melt pool fingerprints. In addition, MAM fabrication may result in defects such as porosity, incomplete processing of the feedstock (e.g., lack of fusion in melt-based methods), and oxide inclusions. Heat treatments may further evolve the microstructure, microsegregation, and stresses within the component. Furthermore, MAM components have a rough surface with feature sizes on the order of the feedstock material, as opposed to smooth surfaces resulting from conventional machining and forming operations. As a result, the corrosion behavior of MAM components will likely be significantly different from that of conventionally formed components. Corrosive environments for structural materials within advanced reactor environments include molten fluoride and chloride salts, liquid sodium and lead-bismuth, and high-temperature helium. The Advanced Materials and Manufacturing Technologies program within the Department of Nuclear Energy in the United States Department of Energy is assessing the unique concerns of MAM component corrosion and testing methodologies in advanced nuclear reactor environments. We discuss these concerns and testing strategies in this paper.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Detection of Off-Gassed Products From Molten Salts Using Laser-Induced Breakdown Spectroscopy

The detection of off-gassed sodium from molten sodium nitrate (NaNO 3 ) at temperatures between 330 °C and 505 °C and off-gassed calcium from molten lithium chloride–potassium chloride eutectic (LKE) mixtures at 510 °C with laser-induced breakdown spectroscopy (LIBS) was demonstrated. NaNO 3 and LKE samples were melted in a custom-built crucible that promoted the generation of off-gassed products from the molten sample. The off-gassed products were analyzed with a LIBS system designed to probe the high-temperature environment. Na D emission lines, Na(I)588.99 nm and Na(I) 589.59 nm, were detected from the NaNO 3 samples after reaching a temperature threshold, which indicated the occurrence of phase change. In LKE mixtures, the detection of Ca impurities at a concentration of 78 mg/kg was possible using the emission lines Ca(II) 393.66 nm and Ca(II) 395.85 nm. Furthermore, this work demonstrates the real-time monitoring capabilities of LIBS in high-temperature environments that simulate the conditions of molten salt reactors.

42 ENGINEERING↗
DOE OSTI2020

Accelerating Large-Format Metal Additive Manufacturing: How Controls R&D is Driving Speed, Scale, and Efficiency

This article highlights work at Oak Ridge National Laboratory’s Manufacturing Demonstration Facility to develop closed-loop, feedback control for laser-wire based Directed Energy Deposition, a form of metal Big Area Additive Manufacturing (m-BAAM), a process being developed in partnership with GKN Aerospace specifically for the production of Ti-6Al-4V pre-forms for aerospace components. A large-scale structural demonstrator component is presented as a case-study in which not just control, but the entire 3D printing workflow for m-BAAM is discussed in detail, including design principles for large-format metal AM, toolpath generation, parameter development, process control, and system operation, as well as post-print net-shape geometric analysis and finish machining. In terms of control, a multi-sensor approach has been utilized to measure both layer height and melt pool size, and multiple modes of closed-loop control have been developed to manipulate process parameters (laser power, print speed, deposition rate) to control these variables. Layer height control and melt pool size control have yielded excellent local (intralayer) and global (component-level) geometry control, and the impact of melt pool size control in particular on thermal gradients and material properties is the subject of continuing research. Further, these modes of control have allowed the process to advance to higher deposition rates (exceeding 7.5 lb/hr), larger parts (1-meter scale), shorter build times, and higher overall efficiency. The control modes are examined individually, highlighting their development, demonstration, and lessons learned, and it is shown how they operate concurrently to enable the printing of a large-scale, near net shape Ti-6Al-4V component.

Gibson, Brian↗
DOE OSTI2024

Phase separation during the direct powder bed fusion of SiC

Powder bed fusion (PBF) is an attractive additive manufacturing option for fabrication of SiC object with complex geometries. However, the density and microstructure controls remain a challenge. This study is aimed at understanding laser–SiC interactions, with emphasis on microstructure-processing relationships, to identify potential solutions for the process improvement. SiC tubes were fabricated by PBF of pure SiC powders without sintering additives. Further, comprehensive analysis by X-ray diffraction, Raman spectroscopy, and electron microscopy indicated that binding of SiC particles was achieved by incongruent melting of SiC to a Si/C mixture containing SiC micro- and nanocrystallites. The phase evolution under laser irradiation of SiC was explained by phase diagrams. This study uncovered the PBF SiC microstructure at different length scales and the relationship between the microstructure and the processing parameters.

36 MATERIALS SCIENCE↗
DOE OSTI2020

In Situ Analysis of Laser Powder Bed Fusion Using Simultaneous High-Speed Infrared and X-ray Imaging

Laser powder bed fusion is a metal additive manufacturing technique that has received significant scientific and industrial attention over the past decades. However, the quality and reproducibility of parts manufactured by this technique is still a problem. Overcoming this issue requires an understanding of multiple complex physical phenomena which occur simultaneously during the process. Here, we illustrate a powerful new technique which synchronizes high-speed x-ray imaging with high-speed infrared imaging to study laser powder bed fusion processes in real time. Using this technique, we demonstrate the simultaneous observation of multiple phenomena including three-dimensional melt pool visualization, vapor plume dynamics, spatter formation, thermal history, and point cooling rates. The paired observation of these dynamic phenomena is critical to understanding the fundamentals of laser powder bed fusion, and the overall impact of process parameters on print quality.

36 MATERIALS SCIENCE↗
NASA NTRS2022

Laser Patterning Assisted Devitrification and Domain Engineering of Amorphous and Nanocrystalline Alloys

We have investigated laser-patterning and devitrification as a novel method to realize emergent properties in modified regions at the ribbon surface consisting of periodic localized laser spots thermally treated under rapid heating and cooling conditions. Fe-based amorphous ribbons were annealed for systematically varied laser power. Extremely high heating and cooling rates on the order of 10(exp 8)-10(exp 10)K/s have been estimated by finite element analysis simulations. Observations suggest surface melting followed by rapid solidification fast enough to quench and form an amorphous structure upon cooling. Diffusion of heat occurs from the laser irradiated surface region so that a finite volume of material surrounding this region rises in temperature above the crystallization temperature relevant for conventional isothermal annealing experiments. The underlying mechanism of laser annealing and consequences of heat transients involved are discussed in terms of impacts upon micro/nanostructure, residual stresses, and magnetic domain structure surrounding the laser irradiated region. The study illustrates the potential to exploit spatially optimized phase transformations in a scalable manufacturing process of amorphous and nanocrystalline alloys to locally access otherwise inaccessible extreme heating and cooling rates.

Amorphous ribbons↗