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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 739 records · Page 41
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Detecting missing struts in metallic micro-lattices using high speed melt pool thermal monitoring

Metal lattices are an important class of cellular materials that offer great advantages by providing high-strength and lightweight structures as compared to bulk materials. Progress in additive manufacturing techniques has led to increased complexity in design and shape of produced objects and is greatly beneficial for the development of metallic lattice structures. However additive manufacturing of lattices suffers from unpredictable defect creation that can compromise its mechanical integrity. Although post-build inspection techniques can provide quality assurance of the process, accurate assessment can be technically challenging, time consuming and costly. In this work, we investigate the use of high-speed measurements of thermal emission from the melt pool to identify defective individual struts formed with a missing bottom half in an otherwise fully built lattice structure produced with laser powder bed fusion. Surprisingly, results indicate lower photodiode signal, suggesting colder melt pool surface temperature, when printing struts with missing bottom half as compared to nominal struts. Additional thermographic imaging and multi-physics simulations reveal that the low photodiode signal is accompanied by presence of hot spatters carrying heat away from detection and continuous avalanche of powder on the melt pool. Based on these observations, a method was developed to identify defective individual struts with missing bottom half in full built lattices. This prediction approach provides valuable insights about part quality which are important for process qualification and illustrates the utility of melt pool thermal emission monitoring for identifying specific defects introduced by laser powder bed fusion.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Ability to Simulate Absorption and Melt Pool Dynamics for Laser Melting of Bare Aluminum Plate: Results and Insights from the 2022 Asynchronous AM-Bench Challenge

The 2022 Asynchronous AM-Bench challenge was designed to test the ability of simulations to accurately predict laser power absorption as well as various melt pool behaviors (width, depth, and solidification) during laser melting of solid metal during stationary and scanned laser illumination. In this challenge, participants were asked to predict a series of experimental outcomes. Experimental data were obtained from a series of experiments performed at the Advanced Photon Source at Argonne National Laboratories in 2019. These experiments combined integrating sphere radiometry with high-speed X-ray imaging, allowing for the simultaneous recording of absolute laser power absorption and two-dimensional, projected images of the melt pool. All challenge problems were based on experiments using bare aluminum solid metal. Participants were provided with pertinent experimental information like laser power, scan speed, laser spot size, and material composition. Additionally, participants were given absorptance and X-ray imaging data from stationary and scanned laser experiments on solid Ti–6Al–4V that could be used for testing their models before attempting challenge problems. In total, this challenge received 56 submissions from eight different research groups for eight individual challenge problems. The data for this challenge, and associated information, are available for download from the NIST Public Data Repository. This paper summarizes the results from the 2022 Asynchronous AM-Bench challenge as well as discusses the lessons learned to help inform future challenges.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Demonstrating imaging plate detector stacks for proton radiography using exploding pusher capsules

A new detector design has been fielded on the Omega-60 laser facility using a D 3 He backlighter capsule to radiograph a magnetized experiment. D 3 He capsules produce a low flux (~ 10 8 total yield in 4π) of protons requiring detectors with close-to single-particle sensitivity to be employed. The new detector stack consisted of both imaging plate (IP) and CR-39 to detect 14.7 MeV protons where, historically, only CR-39 has been used. IP is sensitive to significant contributions in signal from both x-rays and protons so additional filtering has to be added to attenuate the x-rays. Here, the signals and features observed from a single shot are detected by both IP and CR-39, giving confirmation that it is protons creating the signatures on the IP. Measurements of PSL/pixel are used to calculate approximate on-shot proton yields and agree with commonly measured yields. A second IP is used at the rear of the stack to measure, and subsequently remove, a background signal. The spatial resolution at the IP is limited, primarily, by a range of proton energies with varying deflections being recorded at the detector, causing potential ‘blurring’ of features. We find for this setup that the blurring effect is less than the smallest identifiable features observed at the detector, and therefore of minimal impact. A large benefit to this new stack design is that IP can be scanned and processed on much faster timescales than CR-39 allowing for prompt shot feedback. Future designs and modifications to the stack design fielded on this experiment could help improve the contrast of the radiograph on IP, as well as detecting protons produced at alternative energies.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2026

Grayscale projection two-photon lithography using sub-diffraction motifs for ultrafast and precise nanoscale 3D printing

Rapid and high-fidelity nanoscale 3D printing is highly desirable, but it is difficult due to the tradeoff between speed and accuracy. Although optical projection techniques can massively scale up printing, fidelity is compromised due to the difficulty in precisely controlling the light dosage over the entire field. This challenge is typically addressed by using multiple projections, but it slows down printing. Here, we present grayscale projection two-photon lithography to overcome this tradeoff. Despite using a binary mask, it enables projecting more than 15,000 focal spots, each with independently tunable intensity. It advantageously leverages constraints imposed by optical diffraction to achieve grayscale tuning over the entire field at once. By directly tuning the focal spot intensities, we demonstrate suppression of proximity effects, compensation of non-uniform illumination, compensation of stitching artefacts, and rapid 3D printing with a single femtosecond pulse per layer. We demonstrate printing of nanowires as thin as 55 nm and achieve rates of 1.7 billion voxels/s and 215 mm 3 /hr.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Modeling study of divertor particle flow pattern and in–out plasma density asymmetry due to drifts with SOLPS and BOUT++

A study of the effects of drifts on the particle flow pattern and in–out divertor plasma density asymmetry for L-mode and H-mode plasmas is carried out for EAST discharges by the edge plasma transport codes SOLPS and BOUT++. The simulation of L-mode plasmas is done by SOLPS while the simulation of H-mode plasmas is done by BOUT++. The toroidal magnetic field direction for the simulated discharge is artificially reversed in the codes to study the effects of different drift directions on the divertor particle flow pattern and the in–out asymmetry of divertor plasma density. The divertor particle flows induced by diamagnetic and E × B drifts are found to have similar directions in the divertor region for the same discharge. The directions of the flows induced by drifts would be reversed with the reverse of toroidal magnetic field direction. The diamagnetic drift seems to have no effect on the in–out asymmetry of divertor plasma density due to its divergence-free nature. However, the E × B drift could result in a pronounced asymmetry of plasma density between the inner and outer divertor targets. The density in–out asymmetry caused by E × B drift is reversed with the reverse of E × B drift flow direction. Detailed analysis shows that the radial component of the E × B drift flow is the main cause of density asymmetry. The results from the simulation of H-mode plasmas with BOUT++ are similar to those of the L-mode plasmas with SOLPS except that the drift effects seem to be slightly larger in the H-mode plasmas compared to the L-mode plasmas.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

Improvement in the spatial resolution of heavy ion beam probe measurements through application of ion optics

A technique for more accurately modeling and improving the spatial resolution of heavy ion beam probe measurements is described. We use a set of particle trajectories to numerically determine the focusing properties of a complicated three-dimensional magnetic field and characterize those properties with a transfer matrix. We then modify the transfer matrix approach of traditional ion optics to include a parameter that describes the ionization location of the detected ions. The ion optics model calculated using this technique enables a more accurate description of the particle trajectories than previously feasible. The model also allows one to easily determine an initial beam focus that could be used during experimental operation to optimize the spatial resolution of measurements. The technique has been applied to the design of a heavy ion beam probe diagnostic for the Wendelstein 7-X stellarator and improvements in the modeled spatial resolution by a factor of about 2 over previous estimates are possible. As a result, the improved spatial resolution will enable measurements of plasma fluctuations with smaller wavelengths than would otherwise be possible.

43 PARTICLE ACCELERATORS↗
DOE OSTI2022

A study of space charge induced non-linearity in the Single Line Of Sight camera

We report a new generation of gated x-ray detectors at the National Ignition Facility has brought faster, enhanced imaging capabilities. Their performance is currently limited by the amount of signal they can be operated with before space charge effects in their electron tube start to compromise their temporal and spatial response. We present a technique to characterize this phenomenon and apply it to a prototype of such systems, the Single Line Of Sight camera. Results of this characterization are used to benchmark Particle In Cell simulations of the electrons drifting inside the detector, which are found to well reproduce experimental data. These simulations are then employed to predict the optimum photon flux to the camera, with the goal to increase the quality of the images obtained on an experimental campaign while preventing the appearance of deleterious effects. They also offer some insight into some of the improvements that can be brought to the new pulse-dilation systems being built at Lawrence Livermore National Laboratory

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2021

Experimentally probing the extremes of droplet-on-demand printability via liquid metals

The liquid metal jetting droplet-on-demand technology provides many potential benefits to metal additive manufacturing. However, much is left to understand the operational margins to reliably create stable, satellite-free droplets. We elucidate these margins by experimentally probing the unexplored extremities of a recently proposed printability window based on the jet Weber (Wejet) and Ohnesorge (Z = 1/Oh) numbers. We generated stable droplets for 2 ≲ Wejet ≲ 4 for all tested Z = 339 to 2526—well beyond the bounds of any previously published printability window—suggesting that additional physics may be needed to understand droplet-on-demand in the high Z regime.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Emission phases of implosion sources for x-ray absorption fine structure spectroscopy

At the Laboratory for Laser Energetics' Omega Laser Facility, thin plastic shells were directly driven with ∼20 kJ resulting in a time-integrated x-ray yield of ∼1012 ph/eV/sr at 7 keV. Using temporally, spatially, and spectrally discriminating diagnostics, three x-ray emission phases were identified: corona emission produced by the laser ablation of the shell, core stagnation, and afterglow emission due to the expanding hot material after stagnation. The newly measured corona and afterglow emission phases account for ∼25% of the total x-ray signal and produce x-ray emission at a different time or larger radius than previously considered. The resulting implications of this additional emission for x-ray absorption fine structure spectroscopy are discussed. Finally, improvements to the laser drive intensity and uniformity produced a factor-of-2 increase in total x-ray emission while decreasing the size of the stagnated core.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2024

Toward an integrated multi-gigahertz ionizing particle diagnostic

Needs arising at both current and future accelerator facilities call for the development of radiation-hardened position-sensing diagnostics that can operate with multi-GHz repetition rates. Such instruments are likely to also have applications in the diagnosis of rapid plasma behavior. Here, building on the recent work of our Advanced Accelerator Diagnostics Collaboration, we are exploring the development of integrated multi-GHz ionizing particle detection systems based on chemical-vapor deposition diamond sensors, with the initial goal of producing a quadrant detector that can determine the intensity and centroid position of a particle beam at a repetition rate between 5 and 10 GHz. Results from our initial high-speed characterization work are presented, including those from a single-channel sensor with a GHz response. Approaches to achieving multi-GHz (5–10 GHz) rate capability, including the design of a dedicated Application Specific Integrated Circuit and the use of 3D RF-solver computer aided design software, are presented and discussed in more detail. 3D RF simulations suggest clean pulses of duration less than 250 ps (FWHM less than 125 ps) can be achieved with the approaches developed by this work.

43 PARTICLE ACCELERATORS↗
DOE OSTI2024

Developing time-resolved x-ray diffraction diagnostics at the National Ignition Facility (invited)

As part of a program to measure phase transition timescales in materials under dynamic compression, we have designed new x-ray imaging diagnostics to record multiple x-ray diffraction measurements during a single laser-driven experiment. Our design places several ns-gated hybrid CMOS (hCMOS) sensors within a few cm of a laser-driven target. The sensors must be protected from an extremely harsh environment, including debris, electromagnetic pulses, and unconverted laser light. Another key challenge is reducing the x-ray background relative to the faint diffraction signal. Building on the success of our predecessor (Target Diffraction In Situ), we implemented a staged approach to platform development. First, we built a demonstration diagnostic (Gated Diffraction Development Diagnostic) with two hCMOS sensors to confirm we could adequately protect them from the harsh environment and also acquire acceptable diffraction data. This allowed the team to quickly assess the risks and address the most significant challenges. Here, we also collected scientifically useful data during development. Leveraging what we learned, we recently developed a much more ambitious instrument (Flexible Imaging Diffraction Diagnostic for Laser Experiments) that can field up to eight hCMOS sensors in a flexible geometry and participate in back-to-back shots at the National Ignition Facility (NIF). The design also allows for future iterations, such as faster hCMOS sensors and an embedded x-ray streak camera. The enhanced capabilities of the new instrument required a much more complex design, and the unexpected issues encountered on the first few shots at NIF remind us that complexity has consequences. Our progress in addressing these challenges is described herein, as is our current focus on improving data quality by reducing x-ray background and quantifying the uncertainties of our diffraction measurements.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Suppressing proximity effects during rapid serial two-photon lithography through tuning of reaction–diffusion kinetics

The ability of two-photon lithography (TPL) to print deterministic nanoporous 3D structures is highly valuable for many applications. However, it is challenging to print such structures rapidly due to the proximity effects that cause closely spaced features to enlarge and merge. A key challenge is the limited understanding of the origins and spatiotemporal dynamics of the long-range proximity effects that extend beyond the optical focal spot. Here, we empirically investigate these proximity effects in serial TPL using custom-made acrylate-based photoresists. We demonstrate that the complex spatiotemporal dynamics of the proximity effects can be explained through the kinetics of the reaction–diffusion photopolymerization mechanisms that underlie the curing process. Specifically, we show that the proximity effects arise due to comparable timescales of reaction and diffusion of oxygen. Furthermore, we demonstrate that long-range proximity effects can be suppressed by introducing phenolic inhibitors, which reduce oxygen consumption through non-inhibiting side reactions and promote faster termination of curing reactions. These insights enabled improving the linewidths from >400 to 260 nm during printing of nanoporous 3D woodpiles at scanning speeds of 50 mm s −1 . Thus, the knowledge generated here can be applied to deterministically tune the proximity effects and enable rapid printing of high-resolution nanoporous 3D structures.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Energy response characterization of current-mode MeV Cherenkov aerogel detectors

Current-mode Cherenkov aerogel detectors have been used to measure time resolved spectra of MeV radiographic x-ray sources and have been considered to replace gas Cherenkov systems. The simulations of the Cherenkov response of aerogel detectors have uncertainties in how to model the complex structure of aerogels. Data from three sites—the Idaho electron beam, the Los Alamos Site electron beam and microtron sources at Los Alamos—have been used to calibrate the relative energy response of 15 aerogels, varying in density from 10 to 430 mg/cm 3 , from incident electrons with energies from 1 to 12 MeV. Detector simulations need to introduce density variation in the aerogels to match the collected data.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2023

Preparation of Macroscopic Low-Density Gold Foams with Good Machinability

Uniform, macroscopic monoliths (ranging from a few millimeters to a centimeter) of low-density gold foams with ~95% porosity and ~10-μm-diameter pores were prepared by the casting of gold-coated polystyrene core-shell particles followed by the thermal removal of the polymer core. The Au foams were composed of unique hollow gold spheres and showed superior mechanical integrity and resilience compared to the foams we previously reported. Highly efficient seeding and electroless gold-plating methods in this study caused a significant morphological transition in the gold coatings from coarse particles to fine particles, and finally, to a continuous layer. A modified, scalable casting approach to form large uniform monoliths (up to ~1-cm diameter) and a gentle baking condition to minimize undesirable densification of the final foams enabled us to develop a simple, efficient synthetic route to nanostructured macroscopic low-density gold foams. To demonstrate the improved mechanical stability and machinability, a representative monolithic Au foam (~0.9 g/cm 3 ) was carefully cut into the hollow cylinder of gold foams by a series of machining and processing steps. Finally, we tried to understand the unique mechanical behaviors and properties of this gold foam by nanoindentation measurement.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

Systematic Source Determination and X-Ray Radiography Detection of Nonuniformities on High-Density Carbon Ablators

Recent deuterium-tritium (D-T)–layered implosion experiments at the National Ignition Facility have achieved a burning plasma and >1-MJ neutron yield. A series of repeat experiments have shown that the degree of performance is very likely dependent on capsule quality, including the quantity of what are collectively termed “high- Z particles.” These particles are detected on a custom-built radiography system, known as the Sagometer, during the final target qualification process. The term particles is misleading, as the source of these nonuniformities in the capsule images is uncertain; the term detection will be used instead. An increased number of D-T targets have been rejected at the final stages of production due to Sagometer detections. Late detections are deleterious in terms of loss of production parts, effort, and overall operating efficiency. In response, we undertook an effort to determine the origin of these detections and to ultimately mitigate target losses caused by them. Through careful testing and analysis, we have determined neither insufficient production cleanliness nor hohlraum shedding is responsible for the detections on the capsule. Here, we determined that the detections are inherent to the capsule and have made efforts to use the Zeiss Xradia to identify them earlier in the production process. While testing revealed the Xradia is not currently sufficient for identifying such particles using radiography images, we continue to look to other forms of metrology to down select the capsules early in the process.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2024

Interfaces enhanced plasma irradiation resistance in CrMoTaWV/W multilayer films through blocking He diffusion

The performance of plasma-facing materials (PFMs) is one of the key factors that significantly impact the stability of operation in fusion reactors. Herein, a new CrMoTaWV/W (high entropy alloy (HEA)/W) multilayer structure is designed as PFM to investigate its resistance to He plasma irradiation. It was observed that the introduction of the interfaces effectively absorbed plenty of He atoms, preventing them from diffusing into the material and delaying the formation of fuzz incubation zone, therefore, enhancing the resistance to plasma irradiation. The thickness transformed to fuzz in the HEA/W multilayer films was observed to be about two-thirds of those in the CrMoTaWV (HEA) film. Additionally, the fuzz growth rates in HEA/W multilayer films are lower than the average growth rate of bulk W and HEA films combined. These findings highlight a promising new avenue for the exploration of high-performance PFMs.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Shapiro steps observed in a two-dimensional Yukawa solid modulated by a one-dimensional vibrational periodic substrate

Depinning dynamics of a two-dimensional (2D) solid dusty plasma modulated by a one-dimensional (1D) vibrational periodic substrate are investigated using Langevin dynamical simulations. As the uniform driving force increases gradually, from the overall drift velocity varying with the driving force, four significant Shapiro steps are discovered. The data analysis results indicate that, when the ratio of the frequency from the drift motion over potential wells to the external frequency from the modulation substrate is close to integers, dynamic mode locking occurs, corresponding to the discovered Shapiro steps. In conclusion, around both termini of the first and fourth Shapiro steps, the transitions are found to be always continuous, however, the transition between the second and third Shapiro steps is discontinuous, probably due to the different arrangements of particles.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗