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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 559 records · Page 31
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Thermomechanical Behavior of Advanced Manufactured Parts, Subcomponents, and Their Weldments for Gen3 CSP

Generation 3 (Gen3) concentrating solar power (CSP) plants may require the use of molten chloride salt storage systems, solar receivers, and supercritical-CO 2 primary heat exchangers (PHX). The temperatures that would be expected in these parts and subcomponents could approach 760°C for hot side and 500°C for cold side at peak operating conditions. With the design limitations, highly corrosion- and creep-resistant alloys are needed for maximizing component lives. This report presents the results for the project "Thermomechanical Behavior of Advanced Manufactured Parts, Subcomponents, and their Weldments for Gen3 CSP", award number DE-EE00036334. In this project, creep enhanced ferritic alloy Grade 91, austenitic stainless-steel (SS) 304H, Ni claddings Ni201 and C22, and nickel-based superalloys Inconel 740H and Haynes 282 and 230 were evaluated for potential applications in Gen3 CSP systems. Advanced manufacturing of these parts, subcomponents and their welds, was investigated and a full technoeconomic analysis was made in comparison to conventional manufacturing techniques. The manufacturing techniques explored are explosion clad welding and combustion synthesis/combustion reaction for transfer pipes, additive manufacturing (AM) including laser-powder bed fusion (L-PBF) and electron beam AM (EBAM) with wire feedstock for PHX and solar receivers, and conventional fusion welding for similar and dissimilar joining of these various parts and subcomponents.

14 SOLAR ENERGY↗
DOE OSTI2024

Multiscale Modeling of Nanoparticle Precipitation in Oxide Dispersion-Strengthened Steels Produced by Laser Powder Bed Fusion

Laser Powder Bed Fusion (LPBF) enables the efficient production of near-net-shape oxide dispersion-strengthened (ODS) alloys, which possess superior mechanical properties due to oxide nanoparticles (e.g., yttrium oxide, Y-O, and yttrium-titanium oxide, Y-Ti-O) embedded in the alloy matrix. To better understand the precipitation mechanisms of the oxide nanoparticles and predict their size distribution under LPBF conditions, we developed an innovative physics-based multiscale modeling strategy that incorporates multiple computational approaches. These include a finite volume method model (Flow3D) to analyze the temperature field and cooling rate of the melt pool during the LPBF process, a density functional theory model to calculate the binding energy of Y-O particles and the temperature-dependent diffusivities of Y and O in molten 316L stainless steel (SS), and a cluster dynamics model to evaluate the kinetic evolution and size distribution of Y-O nanoparticles in as-fabricated 316L SS ODS alloys. The model-predicted particle sizes exhibit good agreement with experimental measurements across various LPBF process parameters, i.e., laser power (110–220 W) and scanning speed (150–900 mm/s), demonstrating the reliability and predictive power of the modeling approach. The multiscale approach can be used to guide the future design of experimental process parameters to control oxide nanoparticle characteristics in LPBF-manufactured ODS alloys. Additionally, our approach introduces a novel strategy for understanding and modeling the thermodynamics and kinetics of precipitation in high-temperature systems, particularly molten alloys.

Wang, Zhengming (ORCID:0000000241627112)↗
DOE OSTI2025

Multi-Beam-Energy Control Unit Based on Triple-Bend Achromats

X-ray free electron lasers (XFELs) are the new generation of particle accelerator-based light sources, capable of producing tunable, high-power X-ray pulses that are increasingly vital across various scientific disciplines. Recently, continuous-wave (CW) XFELs driven by superconducting linear accelerators have garnered significant attention due to their ability to enhance availability by supporting multiple undulator lines simultaneously. In this paper, we introduce a novel delay system comprising four triple-bend achromats (TBAs). This delay system was combined with fast kickers and can be employed to generate electron beams on a bunch-to-bunch basis in a CW-XFEL facility. Based on the parameters of the Shanghai High-Repetition-Rate XFEL and Extreme Light Facility, start-to-end simulations demonstrate that the TBA-based delay system achieves excellent electron beam qualities while providing a wide beam-energy-tuning range from 1.39 to 8 GeV.

43 PARTICLE ACCELERATORS↗
NASA NTRS1980

Laser power beaming for rocket propulsion and airbreathing propulsion

The developing technology of laser power beaming is introduced, and two systems are used as examples of the capabilities of the laser for beamed energy. In the first system, the potential of the laser to power flight systems ranging from hypersonic air-breathing launch vehicles to commercial jet transports is examined. Attention is given to the possibility of an air-breathing propulsion which offers the promise of a global air transportation network independent of kerosene and powered by solar energy. In addition, consideration is given to a new type of rocket propulsion based on the laser's ability to concentrate coherent laser energy to high power densities. Focused laser beams would heat the propellants directly to produce specific impulses approaching ion and MHD rocket levels, and would do so without the burden of a heavy electrical power supply.

Hertzberg, A.↗
DOE OSTI2023

Integration of sensors through additive manufacturing leading to increased efficiencies of gas turbines for power generation and propulsion

To realize the full capability of additively manufactured components in complex energy systems, it is imperative to minimize early component failures during development phases and during operation. Traditional field feedback timelines and offline inspection protocols significantly reduce the design-manufacturing iteration times. To address this specific question, the project developed and demonstrated a method for the integration of sensors into complex components through additive manufacturing. The team used gas turbine engines as a platform, which meets the need of both power generation and propulsion and offer opportunities for cost reductions and efficiency increases. The innovation of this intelligent integration of sensors into complex components uniquely customized to address questions of integrity and durability for additively manufactured components. With real-time sensing data from additively manufactured components, turbine manufacturers will realize higher efficiencies, reduced component failures, and a 30-50% acceleration in product deployment of high efficiency gas turbine components due to a faster reduction in component risk assessment under actual operating conditions. This is a transformative shift towards a data-driven design and qualification of additively manufactured gas turbine components. To directly integrate sensors into additively manufactured components with all the complexities of actual hardware, powder bed fusion (direct metal laser sintering) and laser metal deposition technologies was developed. Validation took take place in two university laboratories both of which contain actual engine hardware and closely simulate a gas turbine prior to demonstrating the technology in a turbine development test. Indeed, two major technologies from this research cold impact turbine systems in the near future: (1) higher efficiency materials and designs enabled by additive manufacturing with 50% faster design to manufacturing cycle time, to enable faster time-to-market targets; and (2) integration of sensors into additively manufactured components enabling broad health and condition based prognostics for faster component and engine risk reduction.

33 ADVANCED PROPULSION SYSTEMS↗
NASA NTRS1978

Rapid laser induced energy transfer in atomic systems

Analytical and experimental studies of the rapid transfer of stored populations from metastable states to selected target states of a different species are reported. Both laser-induced or laser-switched collision and laser-induced two-photon spontaneous emission are described. It is shown that the laser-induced collision method is particularly useful in the visible and UV spectral regions. It has applications in photochemistry, gas-phase kinetics, and in high-power, high-energy gas-phase lasers. The anti-Stokes source is useful in the VUV and soft X-ray spectral regions.

Harris, S. E.↗
DOE OSTI2025

Joint Experimental and Computational Characterization of Sum-Frequency Generation between a Continuous Wave Laser and an Ultrafast Frequency Comb Laser for Tunable Laser Development

Ultrafast optical frequency combs allow for both high spectral and temporal resolution in molecular spectroscopy and have become a powerful tool in many areas of chemistry and physics. Ultrafast lasers and frequency combs generated from ultrafast mode-locked lasers often need to be converted to other wavelengths. Commonly used wavelength conversions are optical parametric oscillators, which require an external optical cavity, and supercontinuum generation combined with optical parametric amplifiers. Whether commercial or home-built, these systems are complex and costly. Here, we investigate an alternative, simple, and easy-to-implement approach to tunable frequency comb ultrafast lasers enabled by new continuous-wave laser technology. Sum-frequency generation between an Nd:YAG continuous-wave laser and a Yb:fiber femtosecond frequency comb in a beta-barium borate (BBO) crystal is explored. The resulting sum-frequency beam is a pulsed frequency comb with the same repetition rate as the Yb:fiber source. SNLO simulation software is used to simulate the results and provide benchmarks for designing future systems to achieve wavelength conversion and tunability in otherwise difficult-to-reach spectral regions.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1981

Cometary particulate analyzer design definition study

A concept for remotely determining the relative abundance of elements contained in cometary particulates collected by a spacecraft was conducted with very encouraging results. The technique utilizes a short high intensity burst of laser radiation to vaporize and ionize collected particulate material. Ions extracted from this laser-produced plasma are analyzed in a time of flight mass spectrometer to yield an atomic mass spectrum representative of the relative abundance of elements in the particulates. A prototype analyzer system was designed, constructed, and tested. Results show that: (1) energy-time focus performs as predicted in improving resolution; (2) power densities sufficient to produce usable ionization efficiencies can be obtained; (3) complex alloys such as stainless steel can be analyzed; and (4) a tiny, simple and reliable laser used in the demonstration easily meets spacecraft power and mass limitations. A mass resolution of 150 was experimentally demonstrated at mass 108, and an analytical extrapolation predicts a resolution sufficient to separate masses 250 and 251.

Utterback, N. G.↗
DOE OSTI2022

The performance of additively manufactured Haynes 282 in supercritical CO 2

The use of supercritical carbon dioxide (sCO 2 ) as a working fluid is garnering interest in next generation power production systems due to the possibility of increased operational efficiencies and lower associated costs. Its implementation requires alloys with excellent high temperature strength and corrosion resistance, which makes Haynes 282® (H282) a suitable candidate. With increasing adoption of additive manufacturing (AM) in the energy industry, there is a need to investigate long-term sCO2 exposure on AM produced materials. Additively manufactured H282 (AM-H282) samples built using laser powder bed fusion in two different orientations were analyzed through imaging, gravimetric analysis, and room-temperature tensile testing before and after 1000-h exposure to CO 2 at 750 °C and 20 MPa. Performed imaging included observation of the sample surfaces and of the material bulk (cross sections) through means of Scanning Electron Microscopy (SEM) and optical microscopy. In comparison to wrought H282, it was found that the exposed material exhibited a similar Cr 2 O 3 oxide protective layer about 2 μm in thickness with additional top-surface TiO 2 oxide and carbon-rich precipitates. It was also similarly observed that internal oxidation was present but limited to a depth of 20 μm, and a 1–3 μm γ’ denuded region appeared to surround all internal and surface oxidation. Thermal aging effects were noted with the precipitation of needle-like structures in the γ/γ’ matrix and a coarsening of the γ’ precipitates from 28 nm to 73 nm. Mass measurements analyzing oxide precipitation revealed a larger increase compared to wrought, representing an approximate 20% difference. Tensile testing results showed similar behavior to wrought with a slight increase in yield strength and a large reduction in elongation in the exposed samples.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Horn Location Sensors for LBNF

The Horn Location Sensor (HLS) system—named for the magnetic focusing horns it monitors, along with other critical beamline elements – is a high-precision alignment system developed for the Long-Baseline Neutrino Facility (LBNF) to support the Deep Underground Neutrino Experiment (DUNE). With minimal maintenance, the HLS can operate reliably in environments with high radiation, and it ensures that key components such as the protective baffle, focusing horns, and beam position monitors are aligned correctly – each essential for maintaining one of the world’s most intense muon-neutrino beams. A high-precision hydrostatic level sensor, a linear variable differential transformer, and INVAR rods are all used in the system to monitor vertical motion and tilt with sub-millimeter accuracy. A novel Sweep Tracker interferometer enhances calibration fidelity by correcting for non-linearities in laser wavelength and scan rate in real time. A critical part of DUNE’s precision alignment and flux prediction requirements, the HLS system initially supports beam power of up to 1.2 MW and can be upgraded to 2.4 MW.

Frequency scanning interferometry↗
NASA NTRS1980

Solar power satellite system definition study. Volume 1: Executive summary, phase 3

Results of a three phase study of the Solar Power Satellite System are summarized. Various options and alternate systems were considered and the following conclusions were reached: antenna mounted solid state transmitters are potentially as cost effective as the klystron approach, althrough limited to 2500 megawatts net output; the free electron laser and optical diode laser appear most promising for laser power transmission; ground antenna siting need not be restricted to below 35 degrees of latitude; and nonrecurring cost reductions attainable by using a smaller Heavy Lift Launch Vehicle are highly attractive.

Source record↗
NASA NTRS2015

Technology Advancement for Active Remote Sensing of Carbon Dioxide from Space Using the ASCENDS CarbonHawk Experiment Simulator: First Results

The ASCENDS CarbonHawk Experiment Simulator (ACES) is a newly developed lidar developed at NASA Langley Research Center and funded by NASA's Earth Science Technology Office (ESTO) Instrument Incubator Program (IIP) that seeks to advance technologies critical to measuring atmospheric column carbon dioxide (CO2) mixing ratios in support of the NASA Active Sensing of CO2 Emissions over Nights, Days, and Seasons (ASCENDS) mission. The technology advancements targeted include: (1) increasing the power-aperture product to approach ASCENDS mission requirements by implementing multi-aperture telescopes and multiple co-aligned laser transmitters; (2) incorporating high-efficiency, high-power Erbium-Doped Fiber Amplifiers (EDFAs); (3) developing and incorporating a high-bandwidth, low-noise HgCdTe detector and transimpedence amplifier (TIA) subsystem capable of long-duration autonomous operation on Global Hawk aircraft, and (4) advancing algorithms for cloud and aerosol discrimination. The ACES instrument architecture is being developed for operation on high-altitude aircraft and will be directly scalable to meet the ASCENDS mission requirements. These technologies are critical towards developing not only spaceborne instruments but also their airborne simulators, with lower platform requirements for size, mass, and power, and with improved instrument performance for the ASCENDS mission. ACES transmits five laser beams: three from commercial EDFAs operating near 1.57 microns, and two from the Exelis oxygen (O2) Raman fiber laser amplifier system operating near 1.26 microns. The three EDFAs are capable of transmitting up to 10 watts average optical output power each and are seeded by compact, low noise, stable, narrow-linewidth laser sources stabilized with respect to a CO2 absorption line using a multi-pass gas absorption cell. The Integrated-Path Differential Absorption (IPDA) lidar approach is used at both wavelengths to independently measure the CO2 and O2 column number densities and retrieve the average column CO2 mixing ratio. The ACES receiver uses three fiber-coupled 17.8-cm diameter athermal telescopes. The transmitter assembly consists of five fiber-coupled laser collimators and an associated Risley prism pair for each laser to co-align the outgoing laser beams and to align them with the telescope field of view. The backscattered return signals collected by the three telescopes are combined in a fiber bundle and sent to a single low noise detector. The detector/TIA development has improved the existing detector subsystem by increasing its bandwidth to 4.7 MHz from 500 kHz and increasing the duration of autonomous, service-free operation periods from 4 hours to >24 hours. The new detector subsystem enables the utilization of higher laser modulation rates, which provides greater flexibility for implementing advanced thin-cloud discrimination algorithms as well as improving range-determination resolution and error reduction. The cloud/aerosol discrimination algorithm development by Langley and Exelis features a new suite of algorithms for the minimization/elimination of bias errors in the return signal induced by the presence of intervening thin clouds. Multiple laser modulation schemes are being tested in an effort to significantly mitigate the effects of thin clouds on the retrieved CO2 column amounts. Full instrument development concluded in the spring of 2014. After ground range tests of the instrument, ACES successfully completed six test flights on the Langley Hu-25 aircraft in July, 2014, and recorded data at multiple altitudes over land and ocean surfaces with and without intervening clouds. Preliminary results from these test flights will be presented in this paper.

Obland, Michael D.↗
NASA NTRS2017

Optical Testing Using Portable Laser Coordinate Measuring Instruments

High precision, portable coordinate measuring instruments (CMI) such as laser radars (LR) and laser trackers (LT) have been used for optical system alignment and integration. The LRs ability to perform a non-contact scan of surfaces was previously utilized to characterize large spherical and aspheric mirrors. In this paper, we explore the use of a CMI as an accurate, fast, robust, and non-contact tool for prescription characterization of powered optical surfaces. Using Nikons MV-224350 LR and Leicas Absolute Tracker AT401402 instruments, proof of concept measurements were performed to characterize a variety of optical components by measuring the actual and apparent, or equivalently the direct and through (DT), coordinates of calibrated metrology targets. Custom macros in metrology software and other data reduction code were developed to compute surface-ray intercepts and surface slopes from the DT shots. The calculated data is fit to an aspheric surface formula to obtain the optimum prescription. The results were compared to the nominal parameters and were crosschecked using LR scans or other approaches. We discuss potential applications across the fields of optical component fabrication and system alignment and testing.

Khreishi, M.↗
DOE OSTI2024

Exploring laser-material interactions of zirconium carbide under additive manufacturing conditions

Zirconium carbide (ZrC) is an ultra-high temperature ceramic with a melting temperature above 3000°C and a broad range of high temperature applications. Given the high melting and sintering temperatures of pure ZrC, producing near-net shape and fully dense parts remains challenging with conventional techniques. In this study, we investigate the fundamental laser-material interactions of ZrC under laser powder bed fusion (LPBF) additive manufacturing (AM) conditions. Normalized enthalpy, a scaling law term that is used in welding and AM literature for detailing laser-material interactions in metallic alloys, was calculated to determine the predictive capabilities of melt pool features in ZrC. Further, the melt pool quality of laser irradiated ZrC was used to compare LPBF relevant laser parameter combinations of laser power, scan speed, and beam diameter. Laser build parameters that resulted in desirable melt pool morphologies were applied to the fabrication of ZrC coupons using LPBF AM. A custom LPBF system was used to determine hatch spacing and layer height parameters that resulted in a fabricated sample with a density of 85% as measured by Archimedes and a Vicker's microhardness of 20.9 ± 1.9 GPa. This investigation reveals the laser-material interactions of ZrC under AM relevant conditions and is the first step towards LPBF fabrication of ZrC parts.

36 MATERIALS SCIENCE↗
NASA NTRS2005

Long-duration Operation of 2-micron Coherent Doppler Lidar in Space

The reliability and lifetime of laser remote sensing systems that can operate autonomously over a sufficiently long period are mainly constrained by the laser diode arrays (LDAs) used for pumping their laser transmitters. The lifetime of a 2-micron coherent lidar operating in space is particularly of concern in lieu of required pump pulse duration of Thulium and Holmium solid state lasers (approx. 1msec) that are considerably longer than those of more widely used 1-micron lasers (< 0.2 msec). A factor of 5 to 10 times longer pulse duration can easily translate to over an order of magnitude shorter lifetime for a typical commercially available high-power 2-D array. Therefore, it is imperative to address the lifetime and reliability of LDAs for pumping 2-micron lasers by exploring all the potential options that significantly prolong their life meeting the required operational lifetime of space-based coherent Doppler lidars. The leading causes of sudden failure and premature degradation of LDAs are intrinsic semiconductor defects, optical facet breakdown resulting from excessive localized heating, and thermo-mechanical stresses due to the extreme thermal cycling of the laser active regions1-2. Long pulse operation grossly amplifies the impact of these failure/degradation causes, particularly the thermo-mechanical stresses due to pulse-to-pulse thermal cycling. Therefore, several experimental setups have been developed to investigate each of the failure mechanisms and causes of premature degradation in order to evaluate various package designs, define the best operating parameters, and to guide the technology advancement, leading to highly reliable and very long lifetime LDAs5. Several areas of improvement in the packaging and fabrication process of laser diodes have already been identified and efforts towards implementing these improvements are well underway. These efforts include the use of advanced high thermal conductivity materials for packaging of laser diode arrays and new fabrication techniques for mechanically attaching laser diode bars and submounts. But even using the existing LDAs, it may be possible to increase the lifetime by careful selection of the package type, number of bars per package and their pitch, operational temperature, and operating parameters such repetition rate, pulsewidth, and applied current. Obviously, the LDA specification and operational parameters will involve a system level trade analysis to ensure that the lidar instrument meets its performance objectives. One goal of this work is to enable such trade analysis by evaluating LDAs from different suppliers in different package types and quantifying their performance as a function of their operational parameters.

Amzajerdian, Farzin↗
DOE OSTI2025

Multi-millijoule hollow-core fiber compression of short-wave infrared pulses to a single cycle

Approaches for efficient pulse compression can enable dramatic increases in the available peak power, as well as enable the generation of isolated attosecond X-ray pulses. Achieving high compression ratios for longer wavelength drivers has, however, been challenging. We present the compression of few-cycle 2.1 µm central wavelength short-wave infrared laser pulses to 6.9 fs with 2.35 mJ pulse energy at a 10 kHz repetition rate. Electric field resolved measurements reveal a single cycle light field oscillation. With a carrier-envelope-phase stability of 131 mrad and average power fluctuations below 1 %, the system constitutes an excellent light source for strong-field experiments and attosecond physics.

Blöchl, Johannes [Ludwig Maximilian Univ. of Munic↗
NASA NTRS1976

Parametric dependence of ion temperature and relative density in the NASA Lewis SUMMA facility

Further hot-ion plasma experiments were conducted in the SUMMA superconducting magnetic mirror facility. A steady-state ExB plasma was formed by applying a strong radially inward dc electric field between cylindrical anodes and hollow cathodes located near the magnetic mirror maxima. Extending the use of water cooling to the hollow cathodes, in addition to the anodes, resulted in higher maximum power input to the plasma. Steady-state hydrogen plasmas with ion kinetic temperatures as high as 830 eV were produced. Functional relations were obtained empirically among the plasma current, voltage, magnetic flux density, ion temperature, and relative ion density. The functional relations were deduced by use of a multiple correlation analysis. Data were obtained for midplane magnetic fields from 0.5 to 3.37 tesla and input power up to 45 kW. Also, initial absolute electron density measurements are reported from a 90 deg Thomson scattering laser system.

Snyder, A.↗
NASA NTRS1976

Parametric dependence of ion temperature and relative density in the NASA Lewis SUMMA facility

Further hot-ion plasma experiments were conducted in the SUMMA superconducting magnetic mirror facility. A steady-state plasma with mutually perpendicular magnetic and electric fields was formed by applying a strong radially inward dc electric field between cylindrical anodes and hollow cathodes located near the magnetic mirror maxima. Extending the use of water cooling to the hollow cathodes, in addition to the anodes, resulted in higher maximum power input to the plasma. Steady-state hydrogen plasmas with ion kinetic temperatures as high as 830 eV were produced. Functional relations were obtained empirically among the plasma current, voltage, magnetic flux density, ion temperature, and relative ion density. The functional relations were deduced by use of a multiple correlation analysis. Data were obtained for midplane magnetic fields from 0.5 to 3.37 tesla and input power up to 45 kW. Also, initial absolute electron density measurements are reported from a 90 deg Thomson scattering laser system.

Snyder, A.↗