Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “laser applications”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 667 records · Page 37
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Advancing GRCop-based Bimetallic Additive Manufacturing to Optimize Component Design and Applications for Liquid Rocket Engines

Additive manufacturing (AM) is advancing many applications of component design for liquid rocket engines. The ability to rapidly design and manufacture components has provided significant opportunities for development and flight programs across the propulsion industry. AM has demonstrated significant advantages that include cost and schedule savings in addition to performance improvements through new design opportunities. While these performance advantages can be in the characteristics of complex design features, they can also be in the form of new materials. AM has been demonstrated in these various component applications using a variety of metal alloys, many of which are traditional alloys for extreme environments. Additional developments were completed using AM to provide new alloys and maturing these material uses for high performance applications. Almost all of the prior developments across component applications have focused on single-alloys in these AM processes. NASA and industry partners have focused in recent years to advance processing to create bimetallic and multicomponent AM processes and materials. The role of multi-alloy AM offers advantages since it can further optimize weight, optimize reliability and performance by increasing the strength to weight ratio of a component, and can optimize materials for various engineering requirements. This is particularly important in liquid rocket engine combustion devices that must reject heat in high heat flux environments yet maintain adequate structural margins under high operational pressure. NASA has been exploring several AM processes, materials, and applications for combustion devices, specifically combustion chambers, injectors, nozzles, and ignition systems. These components require fine geometric features for internal flow or cooling functionality. They experience high thermal gradients across thin-walls and must survive high pressures and temperatures from propellants and the combustion process. A copper-based alloy is normally used to provide high thermal conductivity, but at the detriment of increased weight if used as a single alloy in an AM chamber. Various AM processes were demonstrated on these components using a copper-based alloy/superalloy bimetallic solution. The AM processes being explored individually and in combination for bimetallic applications include Laser Powder Bed Fusion (L-PBF), Laser Powder Directed Energy Deposition (LP-DED), and cold spray. The combination of bimetallic material combinations explored in this research include copper-based material primarily and superalloys, Inconel 625 or NASA HR-1. The various aspects of the additive manufacturing processes and challenges, materials characterization, and the testing of bimetallic components in a relevant environment will be discussed.

Additive Manufacturing↗
NASA NTRSDate not supplied

Optimization of Rocket Engine Components using Multi-Metallic Additive Manufacturing

Additive manufacturing (AM) is advancing many applications of component design for liquid rocket engines. AM has been demonstrated in various rocket component applications using a variety of monolithic metal alloys, many of which are traditional alloys for extreme environments. NASA and industry partners have focused in recent years to advance processing to create bimetallic and multicomponent AM processes and materials. The role of multi-metallic AM offers advantages since it can further optimize weight, optimize reliability and performance by increasing the strength to weight ratio of a component, and can optimize materials for various engineering requirements. NASA’s Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) project has designed and manufactured a series of additively manufactured (AM) coupled combustion chambers, nozzles, and other engine components to advance new AM processes and materials with the goal of reducing cost and schedule for engine manufacturing. These designs incorporated multimetallic AM, which further enabled carbon-fiber composite overwrap to reduce overall thrust chamber assembly (TCA) mass. Various AM processes were demonstrated on these components using a copper-based alloy/superalloy bimetallic solution. The AM processes being explored individually and in combination for bimetallic applications include Laser Powder Bed Fusion (L-PBF), Laser Powder Directed Energy Deposition (LP-DED), and cold spray. The combination of bimetallic material combinations explored in this research include GRCop-based alloys and superalloys, Inconel 625 or NASA HR-1. One unique development that will be presented is the combustion chamber and nozzle as a single component by using freeform integrated DED to build the nozzle directly onto the aft end of the chamber. The various aspects of the additive manufacturing processes and challenges, materials characterization and mechanical testing, and hot-fire testing of bimetallic components in a relevant rocket engine environment will be discussed.

Additive Manufacturing↗
DOE OSTI2024

Creating microfluidic channels functionalized with micro- and nano-scale features via femtosecond laser surface processing

We demonstrate the ability to create functionalized microfluidic channels using femtosecond laser surface processing (FLSP). FLSP is an emerging advanced manufacturing technology used to modify the surface properties of materials directly and permanently by producing self-organized quasi-periodic micro- and nano-scale surface features along with surface and subsurface chemical and grain structure changes. We demonstrate on Hastelloy X that by controlling the laser fluence and pulse count, the depth of the microchannels and height of the FLSP microstructures within the microchannels can be controlled independently.

Ultrashort pulse laser applications, micro- and na↗
NASA NTRS1974

Applications of tunable high energy/pressure pulsed lasers to atmospheric transmission and remote sensing

Atmospheric transmission of high energy C12 O2(16) lasers were improved by pulsed high pressure operation which, due to pressure broadening of laser lines, permits tuning the laser 'off' atmospheric C12 O2(16) absorption lines. Pronounced improvement is shown for horizontal transmission at altitudes above several kilometers, and for vertical transmission through the entire atmosphere. The atmospheric transmission of tuned C12 O2(16) lasers compares favorably with C12 O2(18) isotope lasers and CO lasers. The advantages of tunable, high energy, high pressure pulsed lasers over tunable diode lasers and waveguide lasers, in combining high energies with a large tuning range, are evaluated for certain applications to remote sensing of atmospheric constituents and pollutants. Pulsed operation considerably increases the signal to noise ratio without seriously affecting the high spectral resolution of signal detection obtained with laser heterodyning.

Hess, R. V.↗
DOE OSTI2020

Laser glazing of cold sprayed coatings for the mitigation of stress corrosion cracking in light water reactor (LWR) applications

The effect of laser power, traverse speed, and cold spray coating thickness were examined with the goal of mitigating and repairing stress corrosion cracking (SCC) in light water reactor (LWR) environment. For this purpose, SCC-susceptible Alloy 600 substrate material was coated with SCC-resistant Alloy 690 via the cold spray technique. The cold spray coated substrate was then laser-glazed using various laser parameters. Single pass and multiple pass laser glazed regions were created to determine the effects. For this purpose, the area of the fusion zone, depth of the fusion zone, and elemental composition of the cross section were examined by optical microscopy, scanning electron microscopy, and energy dispersive spectroscopy. Additionally, it was shown that chromium dilution from the laser glazed region into the substrate is not a significant factor in laser glazed cold spray coated samples. Separate laser glazed samples were subjected to ASTM 633C to determine coating adhesion. Finally, by using interrupted SCC crack growth rate tests, it was shown that low traverse speeds and high laser powers produce deep fusion zones within the cold sprayed coating and substrate that can be used to seal pre-existing cracks, thus stopping SCC growth.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Advancing extreme pulsed lasers through measurements: summary of the pulsed laser metrology workshop

In this report we present consensus findings produced during the pulsed laser metrology (PLM) workshop (Boulder, CO, USA, August 2025). The workshop was a meeting of 35 scientists from private industry, academia, and U.S. government to compile a list of the metrology needs to support extreme pulsed laser development and implementation. We define ‘extreme pulsed lasers’ loosely as those with peak powers above 1 TW or multi-Joule pulse energies. Such lasers are being increasingly used and investigated for use in high energy particle acceleration, short wavelength radiation generation, laser-based fusion, etc. The rapid growth of these fields and the proliferation of extreme lasers for these applications, coupled with the extreme electric fields they generate and relative scarcity of such lasers, presents unique challenges to accuracy in their measurement. The PLM workshop was a two-day event designed to hear from users, developers, and researchers on the current state of optical metrology associated with these extreme pulsed lasers. The goal was to identify the most important measurement challenges limiting development and implementation of these lasers in practical applications. We report here the conclusions and recommendations of this workshop. The hope is that this document will become the first of many iterations which track the status of measurement needs supporting extreme pulsed lasers.

Lasers↗
NASA NTRS1985

Pulsed excimer laser processing for cost-effective solar cells

The application of excimer laser in the fabrication of photovoltaic devices was investigated extensively. Processes included junction formation, laser assisted chemical vapor deposition metallization, and laser assisted chemical vapor deposition surface passivation. Results demonstrated that implementation of junction formation by laser annealing in production is feasible because of excellent control in junction depth and quality. Both metallization and surface passivation, however, were found impractical to be considered for manufacturing at this stage.

Wong, David C.↗
DOE OSTI2025

Cost Effectiveness of Laser Powder Bed Fusion for Heavy Duty Applications

ORNL (Contractor) and Cummins Inc. (Participant) collaborated to determine the cost effectiveness of laser powder bed fusion (LPBF) for heavy duty applications. The team demonstrated that coupons can be fabricated with two distinct process parameters i.e., different process parameters for the bulk and surface of the material. This is important for enabling the manufacturing of components in a production environment where the bulk of the material can be processed rapidly while high quality surface finish can minimize post-process machining as well as enable superior fatigue performance if the material were to be used in as-deposited condition.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Generation of radioisotopes for medical applications using high-repetition, high-intensity lasers

We used the PW high-repetition laser facility VEGA-3 at Centro de Láseres Pulsados in Salamanca, with the goal of studying the generation of radioisotopes using laser-driven proton beams. Various types of targets have been irradiated, including in particular several targets containing boron to generate α-particles through the hydrogen–boron fusion reaction. We have successfully identified γ-ray lines from several radioisotopes created by irradiation using laser-generated α-particles or protons including 43 Sc, 44 Sc, 48 Sc, 7 Be, 11 C and 18 F. We show that radioisotope generation can be used as a diagnostic tool to evaluate α-particle generation in laser-driven proton–boron fusion experiments. We also show the production of 11 C radioisotopes, ≈ 6 × 10 6 , and of 44 Sc radioisotopes, ≈ 5 × 10 4 per laser shot. This result can open the way to develop laser-driven radiation sources of radioisotopes for medical applications.

gamma ray spectroscopy↗
NASA NTRS2015

A plasma-based non-intrusive point source for acoustic beamforming applications

A laser-generated plasma acoustic point source is used to directly measure the point spread function (PSF) of a microphone phased array. In beamforming analysis of microphone phased array data, the true acoustic field is convolved with the array's PSF. By directly measuring the PSF, corrections to the array analysis can be computed and applied. The acoustic source is measured in an open-jet aeroacoustic facility to evaluate the effects of sampling rate, microphone installation, source shift, reflections, shear layer refraction and model presence. Results show that measurements exhibit behavior consistent with theory with regard to source shift and shear layer refraction. Application of a measured PSF in beamforming analysis shows the process provides an effective in-situ method for array calibration both with and without flow and allows for corrections to incorporate reflections and scattering. The technique improves the agreement of beamforming results with the true spectrum of a known source, especially in the presence of reflections.

phased array↗
NASA NTRS1977

Laser anemometer signals - Visibility characteristics and application to particle sizing

Investigations have been conducted concerning the characteristics of the visibility function as determined by the parameters of the laser anemometer system and the electromagnetic scattering properties of the particles. Experiments have been performed to evaluate the backscatter visibility of signals from a symmetric, s polarization laser anemometer as a function of the particle diameter and a parameter ratio. The results have been compared with the predictions of an analysis based on Mie's scattering theory. The analysis has also been used to evaluate the effects of the collecting aperture's size and location.

Adrian, R. J.↗
NASA NTRS1971

A relative performance analysis of atmospheric Laser Doppler Velocimeter methods.

Evaluation of the effectiveness of atmospheric applications of a Laser Doppler Velocimeter (LDV) at a wavelength of about 0.5 micrometer in conjunction with dual scatter LDV illuminating techniques, or at a wavelength of 10.6 micrometer with local oscillator LDV illuminating techniques. Equations and examples are given to provide a quantitative basis for LDV system selection and performance criteria in atmospheric research. The comparative study shows that specific ranges and conditions exist where performance of one of the methods is superior to that of the other. It is also pointed out that great care must be exercised in choosing system parameters that optimize a particular LDV designed for atmospheric applications.

Farmer, W. M.↗
NASA NTRS1988

Laser production and heating of plasma for MHD application

Experiments have been made on the production and heating of plasmas by the absorption of laser radiation. These experiments were performed to ascertain the feasibility of using laser-produced or laser-heated plasmas as the input for a magnetohydrodynamic (MHD) generator. Such a system would have a broad application as a laser-to-electricity energy converter for space power transmission. Experiments with a 100-J-pulsed CO2 laser were conducted to investigate the breakdown of argon gas by a high-intensity laser beam, the parameters (electron density and temperature) of the plasma produced, and the formation and propagation of laser-supported detonation (LSD) waves. Experiments were also carried out using a 1-J-pulsed CO2 laser to heat the plasma produced in a shock tube. The shock-tube hydrogen plasma reached electron densities of approximately 10 to the 17th/cu cm and electron temperatures of approximately 1 eV. Absorption of the CO2 laser beam by the plasma was measured, and up to approximately 100 percent absorption was observed. Measurements with a small MHD generator showed that the energy extraction efficiency could be very large with values up to 56 percent being measured.

Jalufka, N. W.↗
NASA NTRS2011

Noncontacting Laser Inspection System for Dimensional Profiling of Space Application Thermal Barriers

A noncontacting, two-dimensional (2-D) laser inspection system has been designed and implemented to dimensionally profile thermal barriers being developed for space vehicle applications. In a vehicle as-installed state, thermal barriers are commonly compressed between load sensitive thermal protection system (TPS) panels to prevent hot gas ingestion through the panel interface during flight. Loads required to compress the thermal barriers are functions of their construction, as well as their dimensional characteristics relative to the gaps in which they are installed. Excessive loads during a mission could damage surrounding TPS panels and have catastrophic consequences. As such, accurate dimensional profiling of thermal barriers prior to use is important. Due to the compliant nature of the thermal barriers, traditional contact measurement techniques (e.g., calipers and micrometers) are subjective and introduce significant error and variability into collected dimensional data. Implementation of a laser inspection system significantly enhanced the method by which thermal barriers are dimensionally profiled, and improved the accuracy and repeatability of collected data. A statistical design of experiments study comparing laser inspection and manual caliper measurement techniques verified these findings.

Taylor, Shawn C.↗
DOE OSTI2022

Applicability of semiclassical methods for modeling laser-enhanced fusion rates in a realistic setting

In the context of the potential laser-induced enhancement to the rates of DHe 3 and DT fusion, we discuss the frequently-used Wentzel-Kramers-Brillouin (WKB) method and the imaginary-time method (ITM). For static external electric fields, we find that these methods predict significant enhancement to the fusion cross section for electric-field strengths > 10 14 V/m, especially at low values (≈ keV) for the enter-of-mass (CoM) energy. When considering dynamic electric fields, this enhancement can be amplified by considering increased photon frequencies. However, we also pro- vide a review of the region of laser-parameter phase space where these semiclassical methods are applicable. Here, we conclude that this allowable region decreases for higher photon frequencies in con-junction with lower values for the electric-field strength, motivating the need for future experiments to test the predictions of these methods and their ranges of validity.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗