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At least 631 records · Page 35

Effects of shielding gas and spot reduction on humping suppression in high-speed laser welding

High-speed laser welding is a crucial process to enhance the production rate of fuel cell fabrication. However, exceeding a critical welding speed leads to defect formation such as humps and root concavities, which degrade weld quality and mechanical performance. This study employed shielding gas and spot reduction approaches to suppress these defects. The relationships between individual defect types and their influence on weld strength were systematically examined. Moreover, in situ high-speed synchrotron X-ray imaging was employed to comprehend the mechanisms of humping mitigation by shielding gas through analysis of instantaneous keyhole and melt pool dynamics. The observations reveal that shielding gas mitigates humping by shortening the molten pool through enhanced surface heat convection and by altering surface tension to prevent melt flow collisions. The effects of shielding gas and spot reduction were further incorporated into the dimensionless humping index (π h ) that describes the humping formation tendency. These findings provide mechanistic insights and quantitative guidance for defect control strategies in high-speed laser welding.

08 HYDROGEN↗

Recent progress in high-temperature superconducting undulators

Considerable effort has been devoted to the development of superconducting undulators (SCUs) intended for particle accelerator-based light sources, including synchrotrons and free electron laser (FEL) facilities. Recently, a high-temperature superconducting (HTS) undulator prototype, consisting of staggered-array Re-Ba-Cu-O bulks, achieved an on-axis sinusoidal magnetic field profile with a peak amplitude B$_0$ of 2.1 T and a period length of 10 mm, resulting in a deflection parameter K = 1.96. Such a short period HTS undulator not only enables the generation of higher-energy photons, but also supports the construction of economically feasible and compact FELs with shorter linear accelerators (LINACs). This article provides a comprehensive review of recent advances in the staggered-array bulk HTS undulator as well as other types of HTS undulators. Furthermore, it offers insights into the development of engineering HTS undulator prototypes designed for deployment in synchrotron and free electron laser (FEL) facilities. We conclude by discussing opportunities for and the challenges facing the use of HTS undulators in practical applications.

43 PARTICLE ACCELERATORS↗

Fiber-Based, Trace-Gas, Laser Transmitter Technology Development for Space

NASA’s Goddard Space Flight Center (GSFC) is working on maturing the technology readiness of a laser transmitter designed for use in atmospheric CO2 remote-sensing. GSFC has been developing an airplane-based CO2 lidar instrument over several years to demonstrate the efficacy of the instrumentation and measurement technique and to link the science models to the instrument performance. The ultimate goal is to make space-based satellite measurements with global coverage. In order to accomplish this, we must demonstrate the technology readiness and performance of the components as well as demonstrate the required power-scaling to make the link with the required signal-to-noise-ratio (SNR). To date, all the instrument components have been shown to have the required performance with the exception of the laser transmitter.In this program we are working on a fiber-based master oscillator power amplifier (MOPA) laser transmitter architecture where we will develop a ruggedized package and perform the relevant environmental tests to demonstrate TRL-6. In this paper we will review our transmitter architecture and progress on the performance and packaging of the laser transmitter.

Laser↗

Miniature velocimeter

Laser velocimeter (LV) designed to use semiconductor-diode laser is 100 times smaller than continuous-wave gas-laser velocimeter permitting mounting within wind-tunnel models or on engine walls. Mini LV uses only 0.4 watts of power and measures velocities with accuracy of 98% or better.

Franke, J. M.↗

Recent experience in seeding transonic/supersonic flows at AEDC

The laser velocimeter has been utilized for several years at the Arnold Engineering and Development Center (AEDC) as a flow diagnostics tool. Most applications, following the initial proof-of-concept experiments, have involved relatively complex unknown flow fields in which the more conventional, intrusive techniques had either not been attempted or had yielded unsatisfactory results. A blunt-base nozzle-afterbody base flow study is discussed as a respresentative example of such applications. A wide variety of problems have been encountered during these tests, many of which have proven to be closely related to the size and/or size distribution of the seeding material within the fluid. Resulting measurement uncertainties could often not be conclusively resolved because of the unknown nature of the flow field. The other experiments listed were conducted to provide known aerodynamic conditions for comparison with the velocimeter results.

Heltsley, F. L.↗

Activities of the NASA/Marshall Space Flight Center pump stage technology team

In order to advance rocket propulsion technology, the Consortium for Computational Fluid Dynamics (CFD) Application in Propulsion Technology has been formed at Marshall Space Flight Center (MSFC). The Consortium consists of three Teams: the turbine stage team, the pump stage team (PST), and the combustion devices team. The PST has formulated and is implementing a plan for pump technology development whose end product will be validated CFD codes suitable for application to pump components, test data suitable for validating CFD codes, and advanced pump components optimized using CFD codes. The PST's work during the fall of 1991 and the winter and spring of 1992 is discussed in this paper. This work is highlighted by CFD analyses of an advanced impeller design and collection of laser two-focus velocimeter data for the Space Shuttle Main Engine High Pressure Fuel Pump impeller.

Garcia, R.↗

CO2 lidar backscatter experiment

The Aerosol/Lidar Science Group of the Remote Sensing Branch engages in experimental and theoretical studies of atmospheric aerosol scattering and atmospheric dynamics, emphasizing Doppler lidar as a primary tool. Activities include field and laboratory measurement and analysis efforts by in-house personnel, coordinated with similar efforts by university and government institutional researchers. The primary focus of activities related to understanding aerosol scattering is the GLObal Backscatter Experiment (GLOBE) program. GLOBE was initiated by NASA in 1986 to support the engineering design, performance simulation, and science planning for the prospective NASA Laser Atmospheric Wind Sounder (LAWS). The most important GLOBE scientific result has been identified of a background aerosol mode with a surprisingly uniform backscatter mixing ratio (backscatter normalized by air density) throughout a deep tropospheric layer. The backscatter magnitude of the background mode evident from the MSFC CW lidar measurements is remarkably similar to that evident from ground-based backscatter profile climatologies obtained by JPL in Pasadena CA, NOAA/WPL in Boulder CO, and by the Royal Signals and Radar Establishment in the United Kingdom. Similar values for the background mode have been inferred from the conversion of in situ aerosol microphysical measurements to backscatter using Mie theory. Little seasonal or hemispheric variation is evident in the survey mission data, as opposed to large variation for clouds, aerosol plums, and the marine boundary layer. Additional features include: localized aerosol residues from dissipated clouds, occasional regions having mass concentrations of nanograms per cubic meter and very low backscatter, and aerosol plumes extending thousands of kilometers and several kilometers deep. Preliminary comparison with meteorological observations thus far indicate correlation between backscatter and water vapor under high humidity conditions. Limited intercomparisons with the Stratospheric Aerosol and Gas Experiment (SAGE) limb extinction sounder shows differences in the troposphere, however, it should be noted that in general SAGE measurements have not yet been validated in the troposphere.

Jarzembski, Maurice A.↗

Shear coaxial injector instability mechanisms

There is no definitive knowledge of which of several concurrent processes ultimately results in unstable combustion within liquid rocket chambers employing shear coaxial injectors. Possible explanations are a detrimental change in the atomization characteristics due to a decrease in the gas-to-liquid velocity ratio, a change in the gas side injector pressure drop allowing acoustic coupling to the propellant feed system or the disappearance of a stabilizing recirculation region at the base of the LOX post. The aim of this research effort is to investigate these proposed mechanisms under conditions comparable to actual engine operation. Spray characterization was accomplished with flash photography and planar laser imaging to examine the overall spray morphology and liquid jet breakup processes and with a PDPA to quantify the spatial distribution of droplet size and mean axial velocity. A simplified stability model based on the Rayleigh criterion was constructed for the flow dynamics occurring within the chamber and injector to evaluate the potential coupling between the chamber and injector acoustic modes and was supported by high frequency measurements of chamber and injector pressure oscillations. To examine recirculation within the LOX post recess, velocity measurements were performed in the recess region by means of LDV. Present experiments were performed under noncombusting conditions using LOX/GH2 stimulants at pressures up to 4 MPa.

Puissant, C.↗

Geoscience Laser Altimetry System (GLAS) Loop Heat Pipe Anomaly and On Orbit Testing

The Geoscience Laser Altimetry System (GLAS) is the sole instrument on the ICESat Satellite. On day 230 of 2003, the GLAS Component Loop Heat Pipe (CLHP) entered a slow circulation mode that resulted in the main electronics box reaching its hot safing temperature, after which the entire instrument was turned off. The CLHP had a propylene working fluid and was actively temperature controlled via a heater on the compensation chamber. The slow circulation mode happened right after a planned propulsive yaw maneuver with the spacecraft. It took several days to recover the CLHP and ensure that it was still operational. The recovery occurred after the entire instrument was cooled to survival temperatures and the CLHP compensation chamber cycled on a survival heater. There are several theories as to why this slow circulation mode exhibited itself, including: accumulation of Non-Condensible Gas (NCG), the secondary wick being under designed or improperly implemented, or an expanded (post-launch) leak across the primary wick. Each of these is discussed in turn, and the secondary wick performance is identified as the most likely source of the anomalous behavior. After the anomaly, the CLHP was controlled to colder temperatures to improve its performance (as the surface tension increases with lower temperature, as does the volume of liquid in the compensation chamber) and only precursor pulses occurred later in the mission. After GLAS s last laser failed, in late 2009, a decision was made to conduct engineering tests of both LHPs to try and duplicate this flight anomaly. The engineering tests consisted of control setpoint changes, sink changes, and one similar propulsive Yaw maneuver. The only test that showed any similar anomaly precursors on the CLHP was the propulsive maneuver followed by a setpoint increase. The ICESat Satellite was placed in a decaying orbit and ended its mission on August 30, 2010 in Barents Sea.

Baker, Charles↗

Terahertz Quantum Cascade Laser With Efficient Coupling and Beam Profile

Quantum cascade lasers (QCLs) are unipolar semiconductor lasers, where the wavelength of emitted radiation is determined by the engineering of quantum states within the conduction band in coupled multiple-quantum-well heterostructures to have the desired energy separation. The recent development of terahertz QCLs has provided a new generation of solid-state sources for radiation in the terahertz frequency range. Terahertz QCLs have been demonstrated from 0.84 to 5.0 THz both in pulsed mode and continuous wave mode (CW mode). The approach employs a resonant-phonon depopulation concept. The metal-metal (MM) waveguide fabrication is performed using Cu-Cu thermo-compression bonding to bond the GaAs/AlGaAs epitaxial layer to a GaAs receptor wafer.

Chattopadhyay, Goutam↗

Material Characterization of Additively Manufactured Components for Rocket Propulsion

To advance Additive Manufacturing (AM) technologies for production of rocket propulsion components the NASA Glenn Research Center (GRC) is applying state of the art characterization techniques to interrogate microstructure and mechanical properties of AM materials and components at various steps in their processing. The materials being investigated for upper stage rocket engines include titanium, copper, and nickel alloys. Additive manufacturing processes include laser powder bed, electron beam powder bed, and electron beam wire fed processes. Various post build thermal treatments, including Hot Isostatic Pressure (HIP), have been studied to understand their influence on microstructure, mechanical properties, and build density. Micro-computed tomography, electron microscopy, and mechanical testing in relevant temperature environments has been performed to develop relationships between build quality, microstructure, and mechanical performance at temperature. A summary of GRCs Additive Manufacturing roles and experimental findings will be presented.

Additive Manufacturing↗

Materials Characterization of Additively Manufactured Components for Rocket Propulsion

To advance Additive Manufacturing (AM) technologies for production of rocket propulsion components the NASA Glenn Research Center (GRC) is applying state of the art characterization techniques to interrogate microstructure and mechanical properties of AM materials and components at various steps in their processing. The materials being investigated for upper stage rocket engines include titanium, copper, and nickel alloys. Additive manufacturing processes include laser powder bed, electron beam powder bed, and electron beam wire fed processes. Various post build thermal treatments, including Hot Isostatic Pressure (HIP), have been studied to understand their influence on microstructure, mechanical properties, and build density. Micro-computed tomography, electron microscopy, and mechanical testing in relevant temperature environments has been performed to develop relationships between build quality, microstructure, and mechanical performance at temperature. A summary of GRC's Additive Manufacturing roles and experimental findings will be presented.

Additive Manufacturing↗

TPSAS-NF1676L-13011-DND

Features of Doppler Wind Lidar - Works by aerosols in atmosphere reflecting light from a pulsed laser beam. - Allows wind measurements from a long distance—offshore wind can be probed from an onshore location. - Laser beam wavelength (2-μm) creates no hazard for the human eye. - NASA lidar technology is unique in laser pulse energy and capability for long-range wind measurements. - Engineered into compact enclosure with unattended operation. - Rugged enough to be flown on research aircraft into hurricanes. - Poised for technology transfer for commercial development.

Grady Koch↗

Selective laser melting of oxide dispersion strengthened MA956 alloy and its surface finishing by magnetic field assisted finishing

Selective laser melting (SLM) is a prominent metal additive manufacturing (AM) capable of processing a myriad of engineering materials with high precision and design freedom. However, similar to other AM processes, poor surface finishing has been an omnipresent problem in SLM technology. In this study, magnetic field assisted finishing (MAF) was used to finish SLM fabricated oxide dispersion strengthened (ODS) MA956, an iron-chromium-aluminum alloy. The effect of laser processing parameters on part density and surface roughness was first studied. Using a multi-objective optimization technique, the optimal parameters to obtain the highest density and lowest surface roughness were determined. Finally, MAF was applied to the parts built with the obtained optimal SLM parameters, but without significant improvement on the surfaces of as-printed samples. Hence, the surfaces of as-printed samples were post-processed (ground) to yield better initial surface conditions prior to MAF. The effect of initial roughness, iron particles size, and abrasive size on MAF performance was studied. Initial roughness had the most dominant effect followed by abrasive size. The underlying mechanism behind the dependency on initial roughness on final surface quality was analyzed by studying the change on the surface profiles with different starting initial roughness. The initial roughness required for MAF to be effective was determined. In conclusion, using the optimal processing conditions, MAF was applied to the post-processed samples to attain the final average surface roughness (R a ) as little as 0.36 μm starting from initial average roughness (R a ) of 1.53 μm.

36 MATERIALS SCIENCE↗

Near-complete extraction of maximum stored energy from large-core fibers using coherent pulse stacking amplification of femtosecond pulses

High field science relies on ultrashort pulse lasers with multi-joule pulse energies for studying light–matter interactions under extreme conditions and for driving particle accelerators and secondary radiation sources of x rays, gamma rays, neutrons, positrons, muons, and protons. Next-generation laser drivers will require a 10 3 -10 4 times increase in pulse repetition rates, producing multi-joule energies at multi-kilowatt average powers to enable practical applications in nuclear engineering, advanced materials, medicine, biology, homeland security, and high-energy physics. Spatially coherently combined femtosecond fiber lasers are recognized as a pathway to these next-generation drivers, with significant practical advantages including high efficiency and the possibility of compact integration. However, chirped pulse amplification in fibers is capable of extracting only a small fraction (usually ~1%) of the maximum stored energy. Here we demonstrate near-complete maximum stored energy extraction with low accumulated nonlinearity from a large-core fiber amplifier using coherent pulse stacking amplification. We have amplified a 81-pulse stacking burst in a 85 µm core chirally coupled core Yb-doped fiber, extracting up to 9.5 mJ (~90% of stored energy) with < 4.5 radians of accumulated nonlinear phase, temporally combined this burst into a single pulse, and achieved 4.2 mJ pulses of 313 fs bandwidth-limited duration after compression. This represents, to our knowledge, the highest energy extracted and compressed into a femtosecond pulse from a single fiber amplifier, enabling approximately two orders of magnitude size reduction of future high-energy coherently spatially combined fiber laser arrays.

47 OTHER INSTRUMENTATION↗

Design and fabrication of an autonomous rendezvous and docking sensor using off-the-shelf hardware

NASA Marshall Space Flight Center (MSFC) has developed and tested an engineering model of an automated rendezvous and docking sensor system composed of a video camera ringed with laser diodes at two wavelengths and a standard remote manipulator system target that has been modified with retro-reflective tape and 830 and 780 mm optical filters. TRW has provided additional engineering analysis, design, and manufacturing support, resulting in a robust, low cost, automated rendezvous and docking sensor design. We have addressed the issue of space qualification using off-the-shelf hardware components. We have also addressed the performance problems of increased signal to noise ratio, increased range, increased frame rate, graceful degradation through component redundancy, and improved range calibration. Next year, we will build a breadboard of this sensor. The phenomenology of the background scene of a target vehicle as viewed against earth and space backgrounds under various lighting conditions will be simulated using the TRW Dynamic Scene Generator Facility (DSGF). Solar illumination angles of the target vehicle and candidate docking target ranging from eclipse to full sun will be explored. The sensor will be transportable for testing at the MSFC Flight Robotics Laboratory (EB24) using the Dynamic Overhead Telerobotic Simulator (DOTS).

Grimm, Gary E.↗

Development of Directed Energy Deposited NASA HR-1 to Optimize Properties for Liquid Rocket Engine Applications

Metal additive manufacturing (AM) processes have been demonstrated to be effective at reducing costs and lead times associated with fabrication of complex propulsion component designs. Laser powder directed energy deposition (LP-DED) is a metal AM technology that has effectively been used to produce a variety of parts for liquid rocket engine applications. The LP-DED technology has enabled new designs and materials for these applications. The National Aeronautics and Space Administration (NASA) has identified the need to develop and advance new materials in unique engine applications such as hydrogen environments. One such metal alloy being developed for these applications is NASA HR-1. A high-strength Fe-Ni based superalloy, NASA HR-1 was designed to resist high pressure hydrogen environment embrittlement, oxidation, and corrosion. Enabled by LP-DED, NASA HR-1 has completed build and heat treatment optimization, characterization, mechanical and thermophysical testing, and hot-fire testing to demonstrate its capability as an alloy used in liquid rocket engine applications. The evolution of the alloy through material characterization analysis and mechanical testing results from development and optimization efforts will be presented.

additive manufacturing↗