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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 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Melt pool temperature measurement and monitoring during laser powder bed fusion based additive manufacturing via single-camera two-wavelength imaging pyrometry (STWIP)

Melt pool (MP) temperature is one of the determining factors and a key signature for evaluating the properties of printed components in metal additive manufacturing (AM). The state-of-the-art measurement systems are hindered, primarily by the large-scale data acquisition and processing demands. In this work, we introduce a novel coaxial, high-speed, single-camera two-wavelength imaging pyrometer (STWIP) system as opposed to the typical utilization of multiple cameras for measuring MP temperature profiles in laser powder bed fusion (LPBF) processes. Developed on a commercial LPBF machine (EOS M290), the STWIP system demonstrated its ability to quantitatively monitor the MP temperature and its variation for 50 layers at high framerates (>30,000 fps) for a real-world application (standard fatigue specimens) print. High performance computing is employed to analyze the acquired big data (MP images), for determining each MP's average temperature and 2D temperature profile. The MP temperature evolution in the gage section of a fatigue specimen is also examined at a temporal resolution of 1 ms, by evaluating the MP temperatures in the samples' first, middle, and last layers. This report is the first of its kind on monitoring MP temperature distribution and evolution at such a large, detailed scale for longer durations in practical applications.

42 ENGINEERING↗
DOE OSTI2021

Comparison of pyrometry and thermography for thermal analysis of thermite reactions

This article examines the thermal behavior of a laser ignited thermite composed of aluminum and bismuth trioxide. Temperature data were collected during the reaction using a four-color pyrometer and a high-speed color camera modified for thermography. The two diagnostics were arranged to collect data simultaneously, with similar fields of view and with similar data acquisition rates, so that the two techniques could be directly compared. Results show that at initial and final stages of the reaction, a lower signal-to-noise ratio affects the accuracy of the measured temperatures. Both diagnostics captured the same trends in transient thermal behavior, but the average temperatures measured with thermography were about 750 K higher than those from the pyrometer. This difference was attributed to the lower dynamic range of the thermography camera’s image sensor, which was unable to resolve cooler temperatures in the field of view as well as the photomultiplier tube sensors in the pyrometer. Overall, while the camera could not accurately capture the average temperature of a scene, its ability to capture peak temperatures and spatial data make it the preferred method for tracking thermal behavior in thermite reactions.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Time-resolved nanosecond optical pyrometry of the vapor to plasma transitions in exploding bridgewires

Electrically exploded wires find uses throughout high-energy physics. For example, they are commonly used as high-temperature sources, X-ray generators, and in precision timing detonators. However, the detailed and complete physics that occurs is complex and still poorly understood. A full mechanistic description of these complex phenomena is beyond the scope of a single paper. Instead, we focus on the formation of metal vapor and its transition to plasma. This single transition is commonly assumed to comprise “bridge-burst”. We use a suite of diagnostics including a novel, fiber-based, high-speed, optical pyrometer to better characterize this transition. The primary finding from this project is that peak light output from an exploding wire does not temporally match the peak temperature. Additionally, it is found that peak light does not align with peak bridge-burst voltage and that the peak temperature is not voltage-dependent. These findings are non-intuitive and will allow for the correction of false assumptions previously made about this topic.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2017

Shock initiation of nano-Al/Teflon: High dynamic range pyrometry measurements

In this paper, laser-launched flyer plates (25 μm thick Cu) were used to impact-initiate reactive materials consisting of 40 nm Al particles embedded in Teflon AF polymer (Al/Teflon) on sapphire substrates at a stoichiometric concentration (2.3:1 Teflon:Al), as well as one-half and one-fourth that concentration. A high dynamic range emission spectrometer was used to time and spectrally resolve the emitted light and to determine graybody temperature histories with nanosecond time resolution. At 0.5 km s -1 , first light emission was observed from Teflon, but at 0.6 km s -1 , the emission from Al/Teflon became much more intense, so we assigned the impact threshold for Al/Teflon reactions to be 0.6 (±0.1) km s -1 . The flyer plates produced a 7 ns duration steady shock drive. Emission from shocked Al/Teflon above threshold consisted of two bursts. At the higher impact velocities, the first burst started 15 ns after impact, peaked at 25 ns, and persisted for 75 ns. The second burst started at a few hundred nanoseconds and lasted until 2 μs. The 15 ns start time was exactly the time the flyer plate velocity dropped to zero after impact with sapphire. The first burst was associated with shock-triggered reactions and the second, occurring at ambient pressure, was associated with combustion of leftover material that did not react during shock. The emission spectrum was found to be a good fit to a graybody at all times, allowing temperature histories to be extracted. At 25 ns, the temperature at 0.7 km s -1 and the one-fourth Al load was 3800 K. Those temperatures increased significantly with impact velocity, up to 4600 K, but did not increase as much with Al load. A steady combustion process at 2800 (±100) K was observed in the microsecond range. Finally, the minimal dependence on Al loading indicates that these peak temperatures arise primarily from Al nanoparticles reacting almost independently, since the presence of nearby heat sources had little influence on the peak temperatures.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Imaging pyrometry for most color cameras using a triple pass filter

A simple combination of the Planck blackbody emission law, optical filters, and digital image processing is demonstrated to enable most commercial color cameras (still and video) to be used as an imaging pyrometer for flames and explosions. The hardware and data processing described take advantage of the color filter array (CFA) that is deposited on the surface of the light sensor array present in most digital color cameras. In this work, a triple-pass optical filter incorporated into the camera lens allows light in three 10-nm wide bandpass regions to reach the CFA/light sensor array. These bandpass regions are centered over the maxima in the blue, green, and red transmission regions of the CFA, minimizing the spectral overlap of these regions normally present. A computer algorithm is used to retrieve the blue, green, and red image matrices from camera memory and correct for remaining spectral overlap. A second algorithm calibrates the corrected intensities to a gray body emitter of known temperature, producing a color intensity correction factor for the camera/filter system. The Wien approximation to the Planck blackbody emission law is used to construct temperature images from the three color (blue, green, red) matrices. A short pass filter set eliminates light of wavelengths longer than 750 nm, providing reasonable accuracy (±10%) for temperatures between 1200 and 6000 K. The effectiveness of this system is demonstrated by measuring the temperature of several systems for which the temperature is known.

47 OTHER INSTRUMENTATION↗
DOE OSTI2011

Single-crystal sapphire tubes as economical probes for optical pyrometry in harsh environments

One-end-sealed single-crystal sapphire tubes are presented as a simple, robust, and economical alternative for bulky lightpipe probes. Thermal radiation from a blackbody cavity created at the inner surface of the sealed end is gathered by a simple lens-based collecting system and transmitted via optical fiber to the remote detection unit. Simplicity and applicability of the concept are demonstrated by the combination of commercially available sapphire tubes with a common optical pyrometer. Radiation thermometers with sapphire tubes as invasive probes can be useful for applications requiring immunity to electromagnetic interference, resistance to harsh environments, simple replacement in the case of failure, and enhanced mechanical firmness, enabling wider range probe positioning inside the medium of interest.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗