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At least 559 records · Page 31

Validation of Manufacturing Process Designs for Stamped Microchannel Recuperators

Microchannel recuperators can achieve high-efficiency power cycles and chemical reactions by recovering waste heat from hot turbine exhaust and chemical reaction streams. However, the industrial application of microchannel recuperators are restricted by the high cost of patterning and bonding. The objective of this study was thus to investigate new methods for producing microchannel recuperators for emerging markets. Based on greenfield cost estimates, process designs based on stamping, laser welding and vacuum brazing of 316L stainless steel laminae were found to be more economical than conventional photochemical machining and diffusion bonding. Subsequently, validation experiments were conducted to produce stamped microchannel components using cost model parameters. At a mass flow rate of 0.99 g/s, the test article made with laser welding was found to provide higher effectiveness than the test article produced using vacuum brazing. Preliminary investigations showed that residual stresses during laser welding of the laminae led to significant warpage, collapsing channels and making lamina-to-lamina fit up challenging. In contrast, the test article produced by vacuum brazing of stamped laminae showed no clogging and 4.6% and 10.5% channel height standard deviation for the cold and hot channels, respectively. Channel variation in the vacuum brazing sample was determined to be caused by misregistration of laminae during brazing. In future work, efforts are needed to choose cheaper, more ductile brazing foils as well as design a brazing fixture to improve lamina-to-lamina registration.

42 ENGINEERING↗

Single-mode, All-Solid-State Nd:YAG Laser Pumped UV Converter

In this paper, the status of a high-energy, all solid-state Nd:YAG laser pumped nonlinear optics based UV converter development is discussed. The high-energy UV transmitter technology is being developed for ozone sensing applications from space based platforms using differential lidar technique. The goal is to generate greater than 200 mJ/pulse with 10-50 Hz PRF at wavelengths of 308 nm and 320 nm. A diode-pumped, all-solid-state and single longitudinal mode Nd:YAG laser designed to provide conductively cooled operation at 1064 nm has been built and tested. Currently, this pump laser provides an output pulse energy of >1 J/pulse at 50 Hz PRF and a pulsewidth of 22 ns with an electrical-to-optical system efficiency of greater than 7% and a M(sup 2) value of <2. The single frequency UV converter arrangement basically consists of an IR Optical Parametric Oscillator (OPO) and a Sum Frequency Generator (SFG) setups that are pumped by 532 nm wavelength obtained via Second Harmonic Generation (SHG). In this paper, the operation of an inter cavity SFG with CW laser seeding scheme generating 320 nm wavelength is presented. Efforts are underway to improve conversion efficiency of this mJ class UV converter by modifying the spatial beam profile of the pump laser.

Prasad, Narasimha S.↗

Space Shuttle Boundary Layer Transition Flight Experiment Ground Testing Overview

In support of the Boundary Layer Transition (BLT) Flight Experiment (FE) Project in which a manufactured protuberance tile was installed on the port wing of Space Shuttle Orbiter Discovery for STS-119, STS- 128, STS-131 and STS-133 as well as Space Shuttle Orbiter Endeavour for STS-134, a significant ground test campaign was completed. The primary goals of the test campaign were to provide ground test data to support the planning and safety certification efforts required to fly the flight experiment as well as validation for the collected flight data. These test included Arcjet testing of the tile protuberance, aerothermal testing to determine the boundary layer transition behavior and resultant surface heating and planar laser induced fluorescence (PLIF) testing in order to gain a better understanding of the flow field characteristics associated with the flight experiment. This paper provides an overview of the BLT FE Project ground testing. High-level overviews of the facilities, models, test techniques and data are presented, along with a summary of the insights gained from each test.

Karen T Berger↗

TPSAS-NF1676L-19423-DND

In support of the Boundary Layer Transition (BLT) Flight Experiment (FE) Project in which a manufactured protuberance tile was installed on the port wing of Space Shuttle Orbiter Discovery for STS-119, STS-128, STS-131 and STS-133 as well as Space Shuttle Endeavour for STS-134, a significant wind tunnel test campaign was completed. The primary goals of the test campaign were to provide ground test data to support the planning and safety certification efforts required to fly the flight experiment as well as validation for the collected flight data. These test included Arcjet testing of the tile protuberance, aerothermal testing to determine the boundary layer transition behavior and resultant surface heating and planar laser induced fluorescence (PLIF) testing in order to gain a better understanding of the flow field characteristics of the flight experiment. This paper provides an overview of the BLT FE Project ground testing. High-level overviews of the facilities, models, test techniques and data are presented, along with a summary of the insights gained from each test.

Karen T Berger↗

LASER-BASED MEASUREMENT TOOLS FOR FUTURE ENRICHMENT PLANT SAFEGUARDS

The International Atomic Energy Agency (IAEA) has a long history of testing and using laser-based technologies for a variety of safeguards applications. Notable laser-based on-site applications include: 3-dimensional laser range (3DLR) instruments, used for facility design information and verification (DIV); laser measurements to verify unique labels and detect signs of tampering; and laser spectroscopy, for non-contact process monitoring. The IAEA is also evaluating analytical laboratory instruments, such as laser-ablation inductively-coupled plasma mass spectrometry (LA-ICP-MS) for interrogating individual particles to determine uranium isotopic ratios in collected environment samples. Recent laser technology advancements will likely continue to fuel future IAEA adoption of new and novel laser-based safeguards tools. The Pacific Northwest National Laboratory (PNNL) is currently developing one such tool, called laser ablation, absorption ratio spectrometry (LAARS), for quantitative measurements of uranium material. LAARS uses three tunable diode lasers to simultaneously measure atomic 235U and 238U absorption in an ablation plume created by a fourth pulsed laser. Commercial availability of compact pulsed ablation lasers and the extreme wavelength accuracy and stability of PNNL’s tunable diode laser architecture play a pivotal role in achieving high fidelity LAARS assay measurements. The LAARS method is ultimately targeted for either on-site or laboratory-based 235U relative abundance measurements of destructive assay (DA) samples in support of uranium enrichment plant safeguards. DA samples are currently collected on-site, and then shipped to an analytical laboratory for mass spectrometric assay, because the measurement uncertainty requirements for this application are quite challenging. This paper will present the key elements of the LAARS laser system design, recent assay results on collected uranium hexafluoride (UF6) DA samples, and future operational configurations that may provide immediate on-site DA inspection results or rapid laboratory DA sample screening to prioritize further analysis by mass spectrometry.

IAEA, Safeguards, Uranium Enrichment Plants↗

Prospects for Nonlinear Laser Diagnostics in the Jet Noise Laboratory

Two experiments were conducted to test whether optical methods, which rely on laser beam coherence, would be viable for off-body flow measurement in high-density, compressible-flow wind tunnels. These tests measured the effects of large, unsteady density gradients on laser diagnostics like laser-induced thermal acoustics (LITA). The first test was performed in the Low Speed Aeroacoustics Wind Tunnel (LSAWT) of NASA Langley Research Center's Jet Noise Laboratory (JNL). This flow facility consists of a dual-stream jet engine simulator (with electric heat and propane burners) exhausting into a simulated flight stream, reaching Mach numbers up to 0.32. A laser beam transited the LSAWT flow field and was imaged with a high-speed gated camera to measure beam steering and transverse mode distortion. A second, independent test was performed on a smaller laboratory jet (Mach number < 1.2 and mass flow rate < 0.1 kg/sec). In this test, time-averaged LITA velocimetry and thermometry were performed at the jet exit plane, where the effect of unsteady density gradients is observed on the LITA signal. Both experiments show that LITA (and other diagnostics relying on beam overlap or coherence) faces significant hurdles in the high-density, compressible, and turbulent flow environments similar to those of the JNL.

Herring, Gregory C.↗

Simultaneous Laser-induced Fluorescence of Nitric Oxide and Atomic Oxygen in the Hypersonic Materials Environment Test System Arcjet Facility

Simultaneous nitric oxide (NO) and atomic oxygen (O) laser induced fluorescence (LIF) experiments were performed in the Hypersonic Materials Environmental Test System (HYMETS) facility at the NASA Langley Research Center. The data serves as an experimental database for validation for chemical and thermal nonequilibrium models used in hypersonic flows. Measurements were taken over a wide range of stagnation enthalpies (6.7 - 18.5 MJ/kg) using an Earth atmosphere simulant with a composition of 75% N2, 20% O2, and 5% Ar (by volume). These are the first simultaneous measurements of NO and O LIF to be reported in literature for the HYMETS facility. The maximum O LIF mean signal intensity was observed at a stagnation enthalpy of approximately 12 MJ/kg while the maximum NO LIF mean signal intensity was observed at a stagnation enthalpy of 6.7 MJ/kg. Experimental results were compared to simple fluorescence model that assumes equilibrium conditions in the plenum and frozen chemistry in the isentropic nozzle expansion (Mach 5). The equilibrium calculations were performed using CANTERA v2.1.1 with 16 species. The fluorescence model captured the correlation in mean O and NO LIF signal intensities over the entire range of stagnation enthalpies tested. Very weak correlations between single-shot O and NO LIF intensities were observed in the experiments at all of the stagnation enthalpy conditions.

Johansen, Craig↗

Introduction of laser initiation for the 48-inch Advanced Solid Rocket Motor (ASRM) test motors at Marshall Space Flight Center (MSFC)

The Advanced Solid Rocket Motor is a new design for the Space Shuttle Solid Rocket Booster. The new design will provide more thrust and more payload capability, as well as incorporating many design improvements in all facets of the design and manufacturing process. A 48-inch (diameter) test motor program is part of the ASRM development program. This program has multiple purposes for testing of propellent, insulation, nozzle characteristics, etc. An overview of the evolution of the 48-inch ASRM test motor ignition system which culminated with the implementation of a laser ignition system is presented. The laser system requirements, development, and operation configuration are reviewed in detail.

Zimmerman, Chris J.↗

Nitric Oxide PLIF Measurements in the Hypersonic Materials Environmental Test System (HYMETS)

Planar laser-induced fluorescence (PLIF) of naturally occurring nitric oxide (NO) has been used to obtain instantaneous flow visualization images, and to make both radial and axial velocity measurements in the HYMETS (Hypersonic Materials Environmental Test System) 400 kW arc-heated wind tunnel at NASA Langley Research Center. This represents the first application of NO PLIF flow visualization in HYMETS. Results are presented at selected facility run conditions, including some in a simulated Earth atmosphere (75% nitrogen, 20% oxygen, 5% argon) and others in a simulated Martian atmosphere (71% carbon dioxide, 24% nitrogen, 5% argon), for specific bulk enthalpies ranging from 6.5 MJ/kg to 18.4 MJ/kg. Flow visualization images reveal the presence of large scale unsteady flow structures, and indicate nitric oxide fluorescence signal over more than 70% of the core flow for specific bulk enthalpies below about 11 MJ/kg, but over less than 10% of the core flow for specific bulk enthalpies above about 16 MJ/kg. Axial velocimetry was performed using molecular tagging velocimetry (MTV). Axial velocities of about 3 km/s were measured along the centerline. Radial velocimetry was performed by scanning the wavelength of the narrowband laser and analyzing the resulting Doppler shift. Radial velocities of +/- 0.5 km/s were measured.

Inman, Jennifer A.↗

Laser Wakefield Acceleration: Structural and Dynamic Studies. Final Technical Report ER40954

Particle accelerators enable scientists to study the fundamental structure of the universe, but have become the largest and most expensive of scientific instruments. In this project, we advanced the science and technology of laser-plasma accelerators, which are thousands of times smaller and less expensive than their conventional counterparts. In a laser-plasma accelerator, a powerful laser pulse exerts light pressure on an ionized gas, or plasma, thereby driving an electron density wave, which resembles the wake behind a boat. Electrostatic fields within this plasma wake reach tens of billions of volts per meter, fields far stronger than ordinary non-plasma matter (such as the matter that a conventional accelerator is made of) can withstand. Under the right conditions, stray electrons from the surrounding plasma become trapped within these “wake-fields”, surf them, and acquire energy much faster than is possible in a conventional accelerator. Laser-plasma accelerators thus might herald a new generation of compact, low-cost accelerators for future particle physics, x-ray and medical research. In this project, we made two major advances in the science of laser-plasma accelerators. The first of these was to accelerate electrons beyond 1 gigaelectronvolt (1 GeV) for the first time. In experimental results reported in Nature Communications in 2013, about 1 billion electrons were captured from a tenuous plasma (about 1/100 of atmosphere density) and accelerated to 2 GeV within about one inch, while maintaining less than 5% energy spread, and spreading out less than ½ milliradian (i.e. ½ millimeter per meter of travel). Low energy spread and high beam collimation are important for applications of accelerators as coherent x-ray sources or particle colliders. This advance was made possible by exploiting unique properties of the Texas Petawatt Laser, a powerful laser at the University of Texas at Austin that produces pulses of 150 femtoseconds (1 femtosecond is 10-15 seconds) in duration and 150 Joules in energy (equivalent to the muzzle energy of a small pistol bullet). This duration was well matched to the natural electron density oscillation period of plasma of 1/100 atmospheric density, enabling efficient excitation of a plasma wake, while this energy was sufficient to drive a high-amplitude wake of the right shape to produce an energetic, collimated electron beam. Continuing research is aimed at increasing electron energy even further, increasing the number of electrons captured and accelerated, and developing applications of the compact, multi-GeV accelerator as a coherent, hard x-ray source for materials science, biomedical imaging and homeland security applications. The second major advance under this project was to develop new methods of visualizing the laser-driven plasma wake structures that underlie laser-plasma accelerators. Visualizing these structures is essential to understanding, optimizing and scaling laser-plasma accelerators. Yet prior to work under this project, computer simulations based on estimated initial conditions were the sole source of detailed knowledge of the complex, evolving internal structure of laser-driven plasma wakes. In this project we developed and demonstrated a suite of optical visualization methods based on well-known methods such as holography, streak cameras, and coherence tomography, but adapted to the ultrafast, light-speed, microscopic world of laser-driven plasma wakes. Our methods output images of laser-driven plasma structures in a single laser shot. We first reported snapshots of low-amplitude laser wakes in Nature Physics in 2006. We subsequently reported images of high-amplitude laser-driven plasma “bubbles”, which are important for producing electron beams with low energy spread, in Physical Review Letters in 2010. More recently, we have figured out how to image laser-driven structures that change shape while propagating in a single laser shot. The latter techniques, which use the methods of computerized tomography, were demonstrated on test objects – e.g. laser-driven filaments in air and glass – and reported in Optics Letters in 2013 and Nature Communications in 2014. Their output is a multi-frame movie rather than a snapshot. Continuing research is aimed at applying these tomographic methods directly to evolving laser-driven plasma accelerator structures in our laboratory, then, once perfected, to exporting them to plasma-based accelerator laboratories around the world as standard in-line metrology instruments.

43 PARTICLE ACCELERATORS↗

Design of a high-temperature experiment for evaluating advanced structural materials

This report describes the design of an experiment for evaluating monolithic and composite material specimens in a high-temperature environment and subject to big thermal gradients. The material specimens will be exposed to aerothermal loads that correspond to thermally similar engine operating conditions. Materials evaluated in this study were monolithic nickel alloys and silicon carbide. In addition, composites such as tungsten/copper were evaluated. A facility to provide the test environment has been assembled in the Engine Research Building at the Lewis Research Center. The test section of the facility will permit both regular and Schlieren photography, thermal imaging, and laser Doppler anemometry. The test environment will be products of hydrogen-air combustion at temperatures from about 1200 F to as high as 4000 F. The test chamber pressure will vary up to 60 psia, and the free-stream flow velocity can reach Mach 0.9. The data collected will be used to validate thermal and stress analysis models of the specimen. This process of modeling, testing, and validation is expected to yield enhancements to existing analysis tools and techniques.

Mockler, Theodore T.↗

Oxide_Oxide Ceramic Matrix Composite (CMC) Exhaust Mixer Development in the NASA Environmentally Responsible Aviation (ERA) Project

Rolls-Royce North American Technologies, Inc. (LibertyWorksLW) began considering the development of CMC exhaust forced mixers in 2008, as a means of obtaining reduced weight and hotter operating temperature capability, while minimizing shape distortion during operation, which would improve mixing efficiency and reduce fuel burn. Increased component durability, enhanced ability to fabricate complex-shaped components, and engine noise reduction are other potential advantages of CMC mixers (compared to metallic mixers). In 2010, NASA was pursuing the reduction of NOx emissions, fuel burn, and noise from turbine engines in Phase I of the Environmentally Responsible Aviation (ERA) Project. ERA subtasks, including those focused on CMC components, were formulated with the goal of maturing technology from proof of concept validation (TRL 3) to a systemsubsystem or prototype demonstration in a relevant environment (TRL 6). In April 2010, the NASA Glenn Research Center (GRC) and LibertyWorks jointly initiated a CMC Exhaust System Validation Program within the ERA Project, teaming on CMC exhaust mixer development for subsonic jet engines capable of operating with increased performance. Our initial focus was on designing, fabricating, and characterizing the thrust and acoustic performance of a roughly quarter-scale 16-lobe oxide oxide CMC mixer and tail cone along with a conventional low bypass exhaust nozzle. Support Services, LLC (Allendale, MI) and ATK COI Ceramics, Inc. (COIC, in San Diego, CA) supported the design of a subscale nozzle assembly that consisted of an oxide oxide CMC mixer and center body, with each component mounted on a metallic attachment ring. That design was based upon the operating conditions a mixer would experience in a turbofan engine. Validation of the aerodynamic and acoustic performance of the subscale mixer via testing and the achievement of TRL 4 encouraged the NASALWCOIC team to move to the next phase where a full scale CMC mixer sized for a RR AE3007 engine and a compatible attachment flange were designed, followed by CMC component fabrication by COIC, and vibration testing at GRC under conditions simulating the structural and dynamic environment encountered during engine operation. AFRL (WPAFB) supported this testing by performing 3D laser vibrometry to identify the mixer mode shapes and modal frequencies. The successful fabrication and testing of such a component has been achieved. The CMC mixer demonstrated good durability during vibration testing at room and elevated temperature (TRL5). This has cleared the article for a ground-based test on a Rolls-Royce AE3007 engine, where the performance and benefits of the component can be further assessed.

exhaust nozzles↗

Robustness and printed sensor qualification

A limiting factor of additive manufactured (AM) sensors for in-pile applications is the development of appropriate interconnection and packaging strategies that can maintain reliable performance in extreme environments. Failure mechanisms in these harsh conditions could include, but not limited to, materials interaction (i.e., intermetallic formation) and coefficient of thermal expansion (CTE) mismatch between the individual components of the sensors. To mitigate premature failure and enable the successful sustained operation of AM sensors, non-destructive qualification tests are used as an intermediate process control step used for verifying robustness and reliability of the sensor before they are deployed. A materials system of interest is the use of barium strontium titanium oxide (BST) films on stainless steel 316L (SS316L) substrate. Due to BST’s high dielectric constant and tunable dielectric properties, there is an interest for its application as an insulation/encapsulation layer for capacitive strain gauges when printed on structural materials. Previous work on the BST/SS316L material system, however, showed that the BST cracks when exposed to temperatures up to 600 °C due to CTE mismatch between the printed BST film and the metallic substrate. When comparing different fabrication techniques, less surface cracking was observed in the samples that deposited thinner (i.e., 2-20 μm) than samples that were thicker (i.e., 135 µm – 300 µm). The objective of this report is to establish a qualification process that will determine and address any challenges (i.e., mechanical failure of thick prints) of the AM sensor prior to its application in experimental tests. To demonstrate the qualification process in this report, laser spallation and uniaxial tensile tests using dynamic and quasi-static loading, respectively, will be discussed.

36 - MATERIALS SCIENCE↗

Accuracy estimate of the laser rangefinder for Mars rover

A method was developed to determine the accuracy of a rangefinder when errors exist due to the test setup. An analytic procedure was developed to evaluate actual data from a test performed on the laser rangefinder for the Mars rover project.

Ostroski, T.↗

Diode laser heterodyne observations of silicon monoxide in sunspots - A test of three sunspot models

Absorption features from the 8 micron SiO fundamental (upsilon = 1-0) and hot bands (upsilon = 2-1) have been observed in sunspots at sub-Doppler resolution using a ground-based tunable diode laser heterodyne spectrometer. The observed line widths suggest an upper limit of 0.5 km/s for the microturbulent velocity in sunspot umbrae. Since the silicon monoxide abundance is very sensitive to sunspot temperature, the measured equivalent widths permit an unambiguous determination of the temperature-pressure relation in the upper layers of the umbral atmosphere. In the region of SiO line formation (log P sub g = 3.0-4.5), the results support the sunspot model suggested by Stellmacher and Wiehr (1970).

Glenar, D. A.↗

Rain droplet erosion mechanisms in transparent plastic materials

Tests were conducted to determine the damaging effects of rain erosion on optically transparent materials. The rotating arm test equipment used for the tests is described. Typical transparent materials such as those found in windshields, infrared windows, lasers, and television systems were tested. Nominal velocities of 400, 500, and 600 miles per hour and rainfall conditions of one inch per hour simulated rainfall were used in the tests. It was determined that an 80 percent reduction in laser transmittance can occur in plastics submitted to rain erosion. Significant results of the environmental tests are explained.

Schmitt, G. F., Jr.↗

Nitric Oxide PLIF Measurements in the Hypersonic Materials Environmental Test System (HYMETS)

A nonintrusive laser-based measurement system has been applied for the first time in the HYMETS (Hypersonic Materials Environmental Test System) 400 kW arc-heated wind tunnel at NASA Langley Research Center. Planar laser-induced fluorescence of naturally occurring nitric oxide (NO) has been used to obtain instantaneous flow visualization images, and to make both radial and axial velocity measurements. Results are presented at selected facility run conditions, including some in simulated Earth atmosphere (75% nitrogen, 20% oxygen, 5% argon) and others in simulated Martian atmosphere (71% carbon dioxide, 24% nitrogen, 5% argon), for bulk enthalpies ranging from 6.5 MJ/kg to 18.4 MJ/kg. Flow visualization images reveal the presence of large scale unsteady flow structures, and indicate nitric oxide fluorescence signal over more than 70% of the core flow for bulk enthalpies below about 11 MJ/kg, but over less than 10% of the core flow for bulk enthalpies above about 16 MJ/kg. Axial velocimetry was performed using molecular tagging velocimetry (MTV). Axial velocities of about 3 km/s were measured along the centerline. Radial velocimetry was performed by scanning the wavelength of the narrowband laser and analyzing the resulting Doppler shift. Radial velocities of 0.5km/s were measured.

Inman, Jennifer A.↗

Laser-assisted embedding of all-glass optical fiber sensors into bulk ceramics for high-temperature applications

We develop a laser-assisted sensor embedding process to embed all-glass optical fiber sensors into bulk ceramics for high-temperature applications. A specially designed two-step microchannel was fabricated on an Al 2 O 3 substrate for sensor embedment using a picosecond (ps) laser. An optical fiber Intrinsic Fabry-Perot Interferometer (IFPI) sensor was embedded at the bottom of the microchannel and covered by Al 2 O 3 slurry which was subsequently sintered by a CO 2 laser. The sensor spectrum was in-situ monitored during the laser sintering process to ensure the survival of the sensor and optimize the laser sintering parameters. By testing in furnace through high temperature, the embedded optical fiber shows improved stability after CO 2 laser sealing, resulting in the linear temperature response of the embedded optical fiber IFPI sensor. To improve the embedded IFPI sensor for thermal strain measurement, a dummy fiber was co-embedded with the sensing fiber to improve the mechanical bonding between the sensing fiber and the ceramic substrate so that the thermal strain of the ceramic substrate can apply on the sensing fiber. The response sensitivity, measurement repeatability and high-temperature long-term stability of the embedded optical fiber IFPI sensor were evaluated in this work.

47 OTHER INSTRUMENTATION↗