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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 595 records · Page 33
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

One–Step Fabrication of Nanocrystalline Nanonetwork SnO 2 Gas Sensors by Integrated Multilaser Processing

An integrated multilaser process is developed to fabricate nanocrystalline nanonetwork SnO 2 gas sensors in one integrated procedure, which combines electrodes fabrication, nanomaterials deposition, and postannealing. Interdigit electrodes are fabricated on an Au-coated fused silica substrate using a picosecond (ps) laser, which ablates the Au coating from the back of the substrate to pattern the electrodes. A novel transmitted Ps laser deposition (TPLD) process is designed to deposit SnO 2 nanonetwork on the interdigit electrodes with precise deposition area control under a close target-to-substrate distance. The obtained SnO 2 nanonetwork is in situ postannealed by a CO 2 laser to improve the crystallinity, while the nano morphology and grain size keep intact. To investigate the morphology and formation process of the nanonetwork, the microstructure of the laser-deposited SnO 2 layer is characterized. As a result, the crystallization control of CO 2 laser annealing is investigated through analyzing the Raman spectrum, X-ray diffraction (XRD) patterns, and lattice structures of the samples. By exposed to H 2 atmosphere, the fabricated gas sensor is demonstrated for H 2 monitoring.

08 HYDROGEN↗
DOE OSTI2023

High frequency beam oscillation keyhole dynamics in laser melting revealed by in-situ x-ray imaging

The metal additive manufacturing industry is actively developing instruments and strategies to enable higher productivity, optimal build quality, and controllable as-built microstructure. A beam controlling technique, laser oscillation has shown potential in all these aspects in laser welding; however, few attempts have been made to understand the underlying physics of the oscillating keyholes/melt pools which are the prerequisites for these strategies to become a useful tool for laser-based additive manufacturing processes. Here, to address this gap, we utilized a synchrotron-based X-ray operando technique to image the dynamic keyhole oscillation in Ti-6Al-4V using a miniature powder bed fusion setup. We found good agreement between the experimental observations and simulations performed with a validated Lattice Boltzmann multiphysics model. The study revealed the continuous and periodic fluctuations in the characteristic keyhole parameters that are unique to the oscillating laser beam processing and responsible for the chevron pattern formation at solidification. In particular, despite the intrinsic longer-range fluctuation, the oscillating technique displayed potential for reducing keyhole instability, mitigating porosity formation, and altering surface topology. These insights on the oscillating keyhole dynamics can be useful for the future development and application of this technique.

36 MATERIALS SCIENCE↗
NASA NTRS1983

Quantitative measurement of density and velocity in compressible flows using laser-induced iodine fluorescence

A nonintrusive optical technique for the quantitative measurement of molecular density and velocity at a point or in an entire cross-sectional plane of a compressible flowfield is reported. Iodine molecules, seeded into the flowfield reservoir, are excited by a tunable narrow-bandwidth laser and the resulting spatially-resolved fluorescence is collected by a single- or multiple-element detector. A theoretical model for the iodine laser-induced fluorescence process is essential for quantitative measurements and is developed using a rate-equation approach. Density measurements using laser-induced fluorescence are normally complicated by collisional quenching; however, the theory predicts that the off-resonant fluorescent signal is directly proportional to density. Velocity is directly related to the Doppler shift of the iodine absorption line, determined by monitoring the broadband fluorescent signal as the laser is tuned in frequency. Experiments in a steady supersonic flowfield are compared with numerical calculations to demonstrate the accuracy of the approach for density and velocity measurement and the lack of perturbation to the flowfield by the iodine seeding. Extensions of the current approach to density and velocity measurement in lower Mach number flows, to the measurement of pressure and temperature, and to temporally-resolved measurements are discussed.

Mcdaniel, J. C.↗
NASA NTRS1979

Studies of basic mechanisms occurring in high pressure gases: Applications to high efficiency high power lasers

The atomic fluorine laser was investigated. In the hollow cathode, lasing on Fluorine transitions in the doublet system lasted for up to 80 microns with no signs of self-termination. The excitation process of the laser appears to depend heavily upon the fluorine donor utilized. For instance, a single step process is involved when NF3 is used whereas a two step process is evident for SF6. The details are discussed.

Crane, J. K., III↗
NASA NTRS1986

Droplet field visualization and characterization via digital image analysis

This paper describes techniques that have been developed at JPL for visualization and measurements of droplet fields in a moving airstream. The techniques have been applied to a variety of problems which include simulation of heavy rain conditions in a wind tunnel, engine ingestion of wheel spray, analysis of fuel nozzle sprays and aerodynamic breakup of non-Newtonian liquids. The approach pursued here is direct imaging using a pulsed laser illumination source, followed by digital processing of photographic images. A laser double pulse technique has been used for determination of droplet velocities. Laser induced fluorescence has been used to enhance droplet definition in photographic images. The image processing software developed is capable of distinguishing between out-of-focus and in-focus drops, retaining only the latter for size determination.

Hernan, M. A.↗
DOE OSTI2022

Observation of spatter-induced stochastic lack-of-fusion in laser powder bed fusion using in situ process monitoring

Material produced via additive manufacturing (AM) continues to exhibit variable mechanical properties despite apparent optimization of processing parameters, inhibiting qualification efforts and limiting use in critical applications. Stochastic lack-of-fusion flaws may help explain this variability, but the origin of these seemingly random defects has to this point remained unclear. In this work, we show that spatter particles, material ejected from the laser melt pool, are directly responsible for generating stochastic lack-of-fusion in laser-based powder bed fusion components through the application of spatial statistics. Herein a statistically significant, causal relationship between spatter particles and stochastic lack-of-fusion is established, and the spatial and morphological relationships between spatter and internal flaws are investigated. The occurrence of spatter-induced lack-of-fusion in relation to the inert gas flow and laser trajectory direction is also investigated, and recommendations for mitigating the occurrence of spatter are evaluated.

36 MATERIALS SCIENCE↗
NASA NTRS1982

Studies of atmospheric refraction effects on laser data

The refraction effect from three perspectives was considered. An analysis of the axioms on which the accepted correction algorithms were based was the first priority. The integrity of the meteorological measurements on which the correction model is based was also considered and a large quantity of laser observations was processed in an effort to detect any serious anomalies in them. The effect of refraction errors on geodetic parameters estimated from laser data using the most recent analysis procedures was the focus of the third element of study. The results concentrate on refraction errors which were found to be critical in the eventual use of the data for measurements of crustal dynamics.

Dunn, P. J.↗
NASA NTRS2016

Additive Manufacturing for Affordable Rocket Engines

Additive manufacturing (also known as 3D printing) technology has the potential to drastically reduce costs and lead times associated with the development of complex liquid rocket engine systems. NASA is using 3D printing to manufacture rocket engine components including augmented spark igniters, injectors, turbopumps, and valves. NASA is advancing the process to certify these components for flight. Success Story: MSFC has been developing rocket 3D-printing technology using the Selective Laser Melting (SLM) process. Over the last several years, NASA has built and tested several injectors and combustion chambers. Recently, MSFC has 3D printed an augmented spark igniter for potential use the RS-25 engines that will be used on the Space Launch System. The new design is expected to reduce the cost of the igniter by a factor of four. MSFC has also 3D printed and tested a liquid hydrogen turbopump for potential use on an Upper Stage Engine. Additive manufacturing of the turbopump resulted in a 45% part count reduction. To understanding how the 3D printed parts perform and to certify them for flight, MSFC built a breadboard liquid rocket engine using additive manufactured components including injectors, turbomachinery, and valves. The liquid rocket engine was tested seven times in 2016 using liquid oxygen and liquid hydrogen. In addition to exposing the hardware to harsh environments, engineers learned to design for the new manufacturing technique, taking advantage of its capabilities and gaining awareness of its limitations. Benefit: The 3D-printing technology promises reduced cost and schedule for rocket engines. Cost is a function of complexity, and the most complicated features provide the largest opportunities for cost reductions. This is especially true where brazes or welds can be eliminated. The drastic reduction in part count achievable with 3D printing creates a waterfall effect that reduces the number of processes and drawings, decreases the amount of touch labor required, and increases reliability. When certification is achieved, NASA missions will be able to realize these benefits.

West, Brian↗
NASA NTRS2000

Laser Brazing of High Temperature Braze Alloy

The Space Shuttle Main Engine (SSME) consists of 1080 conical tubes, which are furnace brazed themselves, manifolds, and surrounding structural jacket making almost four miles of braze joints. Subsequent furnace braze cycles are performed due to localized braze voids between the coolant tubes. SSME nozzle experiences extremely high heat flux (180 mW/sq m) during hot fire. Braze voids between coolant tubes may result in hot combustion gas escape causing jacket bulges. The nozzle can be disqualified for flight or result in mission failure if the braze voids exceed the limits. Localized braze processes were considered to eliminate braze voids, however, damage to the parent materials often prohibited use of such process. Being the only manned flight reusable rocket engine, it has stringent requirement on the braze process. Poor braze quality or damage to the parent materials limits the nozzle service life. The objective of this study was to develop a laser brazing process to provide quality, localized braze joints without adverse affect on the parent materials. Gold (Au-Cu-Ni-Pd-Mn) based high temperature braze alloys were used in both powder and wire form. Thin section iron base superalloy A286 tube was used as substrate materials. Different Laser Systems including CO2 (10.6 micrometers, 1kW), ND:YAG (1.06 micrometers, 4kW). and direct diode laser (808nm. 150W) were investigated for brazing process. The laser process variables including wavelength. laser power, travel speed and angle of inclination were optimized according to bead geometry and braze alloy wetting at minimum heat input level, The properties of laser brazing were compared to that of furnace brazing. Microhardness profiles were used for braze joint property comparison between laser and furnace brazing. The cooling rate of laser brazing was compared to furnace brazing based on secondary dendritic arm spacing, Both optical and Scanning Electron Microscope (SEM) were used to evaluate the microstructures of the braze materials and tube substrate. Metallography of the laser braze joint was compared to the furnace braze. SEM Energy Disperse X-Ray Spectra (EDX) and back scattered imaging were used to analyze braze alloy segregation. Although all of the laser systems, CO2, ND:YAG, and direct diode laser produced good braze joint, the direct diode laser was selected for its system simplicity, compactness and portability. Excellent laser and braze alloy coupling is observed with powder alloy compared to braze alloy wire. Good wetting is found with different gold based braze alloys. The laser brazing process can be optimized so that the adverse affect on the parent materials can be eliminated. Metallography of the laser braze joint has shown that quality braze joint was produced with laser brazing process. Penetration of the laser braze to the substrate is at neglectable level. Zero penetration is observed. Microstructure examinations shown that no observable changes of the microstructure (grain structure and precipitation) in the HAZ area between laser braze and furnace braze. Wide gaps can be laser brazed with single pass for up to 0.024 inches. Finer dendritic structure is observed in laser brazing compared with equiaxial and coarser grain of the furnace brazing microstructure. Greater segregation is also found in the furnace braze. Higher hardness of the laser braze joint comparing to furnace braze is observed due to the fast cooling rate and Finer microstructure in the laser brazing. Laser braze joint properties meet or exceed the furnace joint properties. Direct diode laser for thin section tube brazing with high temperature braze alloys have been successfully demonstrated. The laser's high energy density and precise control has shown significant advantages in reducing process heat input to the substrates and provide high quality braze joints comparing to other localized braze process such as torch, TIG, and MPTA processes. Significant cost savings can be realized particularly with localized braze comparing to a full furnace braze cycle.

Gao, Y. P.↗
DOE OSTI2021

Surface and subsurface characterization of laser-interference structured Ti6Al4V

Ti6Al4V specimens were exposed to high-energy laser pulses of 1.24 J/cm 2 fluences per pulse using a two-beam optical configuration to attain laser-interference. In addition to the formation of periodic surface textures by laser-interference, scanning electron microscope (SEM) images demonstrated several microstructural changes on the surface processed. Moreover, the surface and subsurface of Ti6Al4V specimens were characterized for the as-received and laser-interference processed conditions using x-ray photoelectron spectroscopy (XPS) and electron energy dispersive spectroscopy (EDS). The XPS data showed that this laser technique is effective at removal of surface contaminants for Ti6Al4V. The XPS analysis also revealed the formation of an oxy-nitride layer on the laser treated material. Finally, the microstructure analysis indicates that grain refinement, dendrite and twin structures were found near the surface due to laser processing.

36 MATERIALS SCIENCE↗
NASA NTRS1995

Space Applications of Industrial Laser Systems (SAILS)

A program is under way to develop a YAG laser based materials processing workstation to fly in the cargo bay of the Space Shuttle. The system will be capable of cutting and welding steel, aluminum, and Inconel alloys of the type planned for use on Space Station Freedom. As well as demonstrating the ability of a YAG laser to perform remote (fiber-optic delivered) repair and fabrication operations in space, fundamental data will be collected on these interactions for comparison with terrestrial data and models. The flight system, scheduled to fly in 1995, will be constructed as two modules to fit into the standard Get Away Special (GAS) canisters. The first can holds the laser and its power supply, to be constructed by our industrial partner, Lumonics Industrial Processing Division. The second canister has the materials processing workstation and the command and data acquisition subsystems. These components will be provided by groups at the University of Tennessee Space Institute (UTSI) and the University of Waterloo. The cans are linked by a fiber-optic cable which transmits the beam from the laser head to the workstation.

Mueller, Robert E.↗
NASA NTRS1986

Metalization Patterns by Thermal Decomposition

Metal interconnection pattern deposited on integrated circuit or solar cell economically by thermal decomposition of metallo-organic compound. In proposed process beam from laser or quartz lamp swept over substrate in required metalization pattern; wherever beam impinges on substrate, radiant heat decomposes compound, depositing metal. Process requires less costly equipment and less time than conventional metalization. Process readily adaptable to very-large-scale integrated (VLSI) circuits.

Gallagher, B. D.↗
DOE OSTI2025

Solidification cracking of laser melted commercial-purity tungsten

The high melting temperature of tungsten (W) makes it an attractive candidate for energy generation applications; however, its use is limited by its poor ductility at low temperatures. This limitation affects even melt-based additive manufacturing (AM) processes such as laser powder bed fusion (PBF-LB), with as-fabricated pure W exhibiting both longitudinal and transverse cracks. Metallurgical and processing factors that affect these cracks are still being explored. This work utilizes powderless single-tracks on pure W plates made over a range of power and velocity combinations in three unique PBF-LB setups: one with flowing argon, one with continuous vacuum, and an in situ high-speed synchrotron X-ray radiography setup. Each had different oxygen activities in their build environments. Longitudinal cracks with oxides appearing to exude from the crack were found for tracks deposited in a build environment with argon shield gas, while no such cracks were observed for builds conducted in vacuum. A calculation showed that direct oxygen ingress into the melt pool from the build environment is negligible when argon shield gas is present. Thus, incorporation of spatter is a likely mechanism for oxygen ingress into the melt pool. Radiography showed extensive keyholing, spatter generation, and crack formation at keyhole porosity. A heat transfer calculation showed the crack formation time was consistent with cooling below its ductile-to-brittle transition (DBT) temperature. This work identifies solidification cracking as a feasible mechanism in pure W beyond the well-known DBT related cracking.

Materials science↗
NASA NTRS1989

Laser Welding in Space

Solidification type welding process experiments in conditions of microgravity were performed. The role of convection in such phenomena was examined and convective effects in the small volumes obtained in the laser weld zone were observed. Heat transfer within the weld was affected by acceleration level as indicated by the resulting microstructure changes in low gravity. All experiments were performed such that both high and low gravity welds occurred along the same weld beam, allowing the effects of gravity alone to be examined. Results indicate that laser welding in a space environment is feasible and can be safely performed IVA or EVA. Development of the hardware to perform the experiment in a Hitchhiker-g platform is recomended as the next step. This experiment provides NASA with a capable technology for welding needs in space. The resources required to perform this experiment aboard a Shuttle Hitchhiker-pallet are assessed. Over the four year period 1991 to 1994, it is recommended that the task will require 13.6 manyears and $914,900. In addition to demonstrating the technology and ferreting out the problems encountered, it is suggested that NASA will also have a useful laser materials processing facility for working with both the scientific and the engineering aspects of materials processing in space. Several concepts are also included for long-term optimization of available solar power through solar pumping solid state lasers directly for welding power.

Workman, Gary L.↗
NASA NTRS1977

Laser induced photoluminiscence studies of primary photochemical production processes of cometary radicals

A tunable vacuum ultraviolet flash lamp was constructed. This unique flash lamp was coupled with a tunable dye laser detector and permits the experimenter to measure the production rates of ground state radicals as a function of wavelength. A new technique for producing fluorescent radicals was discovered. This technique called multiphoton ultraviolet photodissociation is currently being applied to several problems of both cometary and stratospheric interest. It was demonstrated that NO2 will dissociate to produce an excited fragment and the radiation can possibly be used for remote detection of this species.

Jackson, W. M.↗
NASA NTRS1987

A theoretical evaluation of laser-sustained plasma thruster performance

An extensive numerical experiment has been conducted to evaluate rocket thruster performance using a laser-sustained hydrogen plasma as the propellant. The plasma was sustained using a 30 kW CO2 laser beam operated at 10.6 microns focused inside the thruster. The steady-state Navier-Stokes equations coupled with the laser power absorption process have been solved numerically. A pressure based Navier-Stokes solver using body-fitted coordinate was used to calculate the laser-supported rocket flow which included both recirculating and transonic flow regions. The local thermodynamic equilibrium (LTE) assumption was used for the plasma thermophysical and optical properties. Geometric ray tracing was adopted to describe the laser beam. Several different throat size thrusters operated at 150 and 300 kPa chamber stagnation pressure were studied. It was found that the thruster performance (vacuum specific impulse) was highly dependent on the operating conditions, and a properly designed laser supported thruster can attain a specific impulse around 1500 secs. The heat loading on the thruster wall was also estimated and was in the range of that for a conventional chemical rocket.

Jeng, San-Mou↗
NASA NTRS1980

The hollow-cathode helium-fluorine laser

It is possible to obtain uniform stable long-pulse excitation (in excess of 100 microsec) in gas mixtures involving highly electronegative constituents (SF6, CCl4, NF3, and I2). Such a system was used to investigate the atomic fluorine laser. In the hollow cathode, lasing on fluorine transitions in the doublet system lasted for up to 80 microsec with no signs of the self-termination as reported previously in positive-column devices. The excitation process of the laser appears to depend heavily upon the fluorine donor utilized. For instance, a single-step process is involved when NF3 is used whereas a two-step process is evident for SF6. The details are discussed.

Crane, J. K.↗