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DOE OSTI2021

Localized Defect Detection from Spatially Mapped, In-Situ Process Data With Machine Learning

In powder bed fusion additive manufacturing, machines are often equipped with in-situ sensors to monitor the build environment as well as machine actuators and subsystems. The data from these sensors offer rich information about the consistency of the fabrication process within a build and across builds. This information may be used for process monitoring and defect detection; however, little has been done to leverage this data from the machines for more than just coarse-grained process monitoring. In this work we demonstrate how these inherently temporal data may be mapped spatially by leveraging scan path information. We then train a XGBoost machine learning model to predict localized defects—specifically soot–using only the mapped process data of builds from a laser powder bed fusion process as input features. The XGBoost model offers a feature importance metric that will help to elucidate possible relationships between the process data and observed defects. Finally, we analyze the model performance spatially and rationalize areas of greater and lesser performance.

3D printing↗

DOE OSTI2021

Scaling of oxygen-methane reacting coaxial jets using x-ray fluorescence to measure mixture fraction

Stoichiometric mixing length L s of reacting coaxial jet flames is a critical scaling parameter for liquid rocket engine combustors. Previous studies have shown that L s for shear coaxial flames can be scaled like their non-reacting counterparts using a non-dimensional momentum flux ratio J. In addition, stoichiometric mixing lengths of reacting and nonreacting coaxial jets collapse upon a single line by altering J using an effective outer flow gas density. This effective density is calculated from a modified version of the equivalence principle, originally developed by Tacina and Dahm [1, 2] and accounts for the effects of heat release on mixing. However, previous studies also required a second nonphysical scaling constant S c for the reacting jets, which is not predicted by the equivalence principle [3]. It was originally hypothesized that S c is attributed to the limitation of hydroxyl (OH) planar laser-induced fluorescence, which only infers L s . Direct quantitative measurement of conserved scalar fields using conventional optical diagnostics is difficult due to the lack of a tracer that easily fluoresces, survives high temperature oxygen flames, and is not dominated by quenching effects. To measure a conserved scalar field, this work implements x-ray fluorescence of Kr and Ar tracers to obtain quantitative mixture fraction fields. From these mixture fraction fields, stoichiometric mixing lengths for two CH 4 /O 2 flames are calculated and scaled against nonreacting coaxial mixing lengths using the equivalence principle. By directly measuring the stoichiometric mixing length, it is established that the additional constant is a byproduct of the OH measurement technique and the equivalence principle fully captures the scaling. Finally, comparison with high-fidelity simulation of the flame further supports this conclusion. In addition to further strengthening this scaling method, this work represents the first use of x-ray fluorescence to make quantitative conserved scalar measurements in turbulent flames.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2022

Application of machine learning to sporadic experimental data for understanding epitaxial strain relaxation

Understanding epitaxial strain relaxation is one of the key challenges in functional thin films with strong structure–property relations. Herein, we employ an emerging data analytics approach to quantitatively evaluate the underlying relationships between critical thickness ($h_c$) of strain relaxation and various physical and chemical features, despite the sporadic experimental data points available. First, we have collected and refined the reported $h_c$ of the perovskite oxide thin film/substrate system to construct a consistent sub-dataset which captures a common trend among the varying experimental details. Then, we employ correlation analyses and feature engineering to find the most relevant feature set which includes Poisson's ratio and lattice mismatch. With the insight offered by correlation analyses and feature engineering, machine learning (ML) models have been trained to deduce a decent accuracy, which has been further validated experimentally. In this work, the demonstrated framework is expected to be efficiently extended to the other classes of thin films in understanding $h_c$.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Novel subnanosecond rise, flattop, 100 kV high voltage pulse generator (ASAP-LDRD-22-0122)

We looked to build a new type of 100 kV pulse generator that we hope will avoid many of the problems seen with other commercially available pulse generators. We looked to exploit recent improvements in both lasers and solid-state pulse charge units along with an alternative triggering layout to build something new. For the pulse charging unit, we collaborated with Texas Tech to leverage their knowledge and expertise in pulse transformers and solid-state switching. The final result of the LDRD looks promising. Texas Tech was able to build a pulse charge unit that meets our specifications regarding output, and we were able to integrate it with a switch and a laser to create a device that meets the goals of the LDRD. There is still much work to do to advance the design further and improve reliability, but the proto-type design satisfies the goals we set for this LDRD.

42 ENGINEERING↗

DOE OSTI2021

Lifetime-resolved photon-correlation Fourier spectroscopy

The excited state population of single solid-state emitters is subjected to energy fluctuations around the equilibrium driven by the bath and relaxation through the emission of phonons or photons. Simultaneous measurement of the associated spectral dynamics requires a technique with a high spectral and temporal resolution with an additionally high temporal dynamic range. We propose a pulsed excitation-laser analog of photon-correlation Fourier spectroscopy (PCFS), which extracts the linewidth and spectral diffusion dynamics along the emission lifetime trajectory of the emitter, effectively discriminating spectral dynamics from relaxation and bath fluctuations . This lifetime-resolved PCFS correlates photon-pairs at the output arm of a Michelson interferometer in both their time-delay between laser-excitation and photon-detection T and the time-delay between two photons τ . We propose the utility of the technique for systems with changing relative contributions to the emission from multiple states, for example, quantum emitters exhibiting phonon-mediated exchange between different fine-structure states.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Characterization of the Fusion Zone in Laser Beam Welds on SS304L

Designing a welded joint requires consideration of the welding process, component/assembly structure and weld geometry, material composition, properties, and desired joint performance. The designer must also specify a set of acceptance criteria used to evaluate the welds. This study was conducted to support the design team responsible for specifying the spot weld profile by investigating the relationship between weld process parameters and the weld geometry and properties to further inform design optimization. The subjects of this study are two thin stainless steel 304L (SS304L) components joined by Laser Beam Welding (LBW). The components are the Housing, which contains flexible circuitry, and the Cover that protects the circuitry during handling, installation, and under service loads. Figure 1 illustrates coupon versions of the Cover and Housing used to simulate the interface between these components for weld testing. These coupon representations of assembly components were designed to match the material and relevant geometry related to the welded joint while other features not relevant to the welded joint are excluded.The objective of this study was to characterize the sensitivity of the weld geometry and mechanical properties to the input weld parameters to inform further Finite Element Analysis (FEA) efforts in balancing joint strength against assembly deformation caused by the welding process. Characterization was accomplished by varying laser welding parameters around the current design values and measuring weld geometry on the cross-sections. Nanoindentation with a spherical and flat-ended tip was used on polished section cuts of the weld to obtain direct estimates of the stress-strain response of the Fusion Zone (FZ) for comparison to the Base Metal (BM).

42 ENGINEERING↗

DOE OSTI2020

Efficient Energy Funneling in Quasi‐2D Perovskites: From Light Emission to Lasing

Abstract Quasi‐2D Ruddlesden–Popper halide perovskites with a large exciton binding energy, self‐assembled quantum wells, and high quantum yield draw attention for optoelectronic device applications. Thin films of these quasi‐2D perovskites consist of a mixture of domains having different dimensionality, allowing energy funneling from lower‐dimensional nanosheets (high‐bandgap domains) to 3D nanocrystals (low‐bandgap domains). High‐quality quasi‐2D perovskite (PEA) 2 (FA) 3 Pb 4 Br 13 films are fabricated by solution engineering. Grazing‐incidence wide‐angle X‐ray scattering measurements are conducted to study the crystal orientation, and transient absorption spectroscopy measurements are conducted to study the charge‐carrier dynamics. These data show that highly oriented 2D crystal films have a faster energy transfer from the high‐bandgap domains to the low‐bandgap domains (<0.5 ps) compared to the randomly oriented films. High‐performance light‐emitting diodes can be realized with these highly oriented 2D films. Finally, amplified spontaneous emission with a low threshold 4.16 µJ cm −2 is achieved and distributed feedback lasers are also demonstrated. These results show that it is important to control the morphology of the quasi‐2D films to achieve efficient energy transfer, which is a critical requirement for light‐emitting devices.

Lei, Lei↗

DOE OSTI2024

Inverse design for waveguide dispersion with a differentiable mode solver

Inverse design of optical components based on adjoint sensitivity analysis has the potential to address the most challenging photonic engineering problems. However, existing inverse design tools based on finite-difference-time-domain (FDTD) models are poorly suited for optimizing waveguide modes for adiabatic transformation or perturbative coupling, which lies at the heart of many important photonic devices. Among these, dispersion engineering of optical waveguides is especially challenging in ultrafast and nonlinear optical applications involving broad optical bandwidths and frequency-dependent anisotropic dielectric material response. In this work, we develop gradient back-propagation through a general-purpose electromagnetic eigenmode solver and use it to demonstrate waveguide dispersion optimization for second harmonic generation with maximized phase-matching bandwidth. This optimization of three design parameters converges in eight steps, reducing the computational cost of optimization by ∼100x compared to exhaustive search and identifying new designs for broadband optical frequency doubling of laser sources in the 1.3–1.4 µm wavelength range. Furthermore, we demonstrate that the computational cost of gradient back-propagation is independent of the number of parameters, as required for optimization of complex geometries. This technique enables practical inverse design for a broad range of previously intractable photonic devices.

Gray, Dodd (ORCID:000000030469599X)↗

DOE OSTI2025

Dynamic Nanopeptide Assemblies for Trans-Tympanic Drug Delivery

Aim: Otitis media is a common otolaryngologic diagnosis worldwide. Invasive methods to curtail and treat frequent occurrences are undesirable, thus necessitating the identification and production of a non-invasive approach to treating the disease. Due to tympanic membrane thickness, ototopical drug delivery is challenging. In this preliminary study, formulations integrating nanopeptides and thermoresponsive polymeric hydrogels are utilized to improve the efficiency of trans-tympanic membrane drug delivery. Methods: Peptides were synthesized using standard Fmoc (fluorenylmethoxycarbonyl protecting group) based solid state peptide synthesis on an automated peptide synthesizer. Ciprofloxacin release was simulated using multiwell microplates with porous inserts. Rate of Ciprofloxacin release was measured over a 48-hour period using a 200 uL solution of peptide fibers and Ciprofloxacin at 1 wt% each, and the labeled peptide at 0.1 wt% in PBS at pH of 7.4. The cytotoxicity of the PA (peptide amphiphile, specifically c16-AHL 3 K 3 -CO 2 H) micelle and fiber with and without ciprofloxacin was investigated by examining epidermal keratinocyte viability in the presence of the material at various concentrations. Laser scanning confocal microscopy was performed with excitation of the calcein dye at 485 nm and the PA-TAMRA (rhodamine labeled peptide) at 515 nm. Results: We have demonstrated the potential viability of a self-assembled peptide amphiphile hydrogel capable of transitioning from a network of 1D nanoscale fibers to 0D micelles. This dissociative mechanism of action yields a peptide that is an effective cell penetrating peptide (CPP) while temporally controlling the release of the antibiotic ciprofloxacin. Conclusion: This work highlights the potential utility of the dynamic process of an engineered peptide hydrogel capable of dissociating into CPPs capable of facilitating drug delivery across the tympanic membrane.

cell culture↗

DOE OSTI2021

A critical look at the prediction of the temperature field around a laser-induced melt pool on metallic substrates

The study of microstructure evolution in additive manufacturing of metals would be aided by knowing the thermal history. Since temperature measurements beneath the surface are difficult, estimates are obtained from computational thermo-mechanical models calibrated against traces left in the sample revealed after etching, such as the trace of the melt pool boundary. Here we examine the question of how reliable thermal histories computed from a model that reproduces the melt pool trace are. To this end, we perform experiments in which one of two different laser beams moves with constant velocity and power over a substrate of 17-4PH SS or Ti-6Al-4V, with low enough power to avoid generating a keyhole. We find that thermal histories appear to be reliably computed provided that (a) the power density distribution of the laser beam over the substrate is well characterized, and (b) convective heat transport effects are accounted for. Poor control of the laser beam leads to potentially multiple three-dimensional melt pool shapes compatible with the melt pool trace, and therefore to multiple potential thermal histories. Ignoring convective effects leads to results that are inconsistent with experiments, even for the mild melt pools here.

42 ENGINEERING↗

DOE OSTI2024

Laser micro-machining and damage testing of rounded shadow cone blockers on silica glass for arresting laser damage growth by redirection of light

Structured conical blockers manufactured on optical input surfaces are being used to shadow, and thereby, arrest growth of exit surface damage on large optics for applications in high-energy laser systems to extend their lifetime usage. However, as the size of the Shadow Cone Blocker (SCB) is increased, the deflected light must be carefully managed to prevent consequential damage from downstream intensification. Here, we design and fabricate a distinct input SCB geometry to alleviate this problem, enabling larger damage site mitigation. The demonstrated ~1 mm diameter SCB was manufactured with a convergent approach using a CO 2 pulsed laser ablative scanning sequence on a fused silica window. The SCB design was refined to maximize resistance to both input and exit surface damage initiations on 1 cm thick fused silica windows when exposed to 351 nm irradiation and validated with laser damage testing. The design showed to prevent damage onset to the exit surface for incident fluences on the SCB of 10.7 ± 1.3 J·cm -2 and is resistant to damage on the input surface exceeding 30 J·cm -2 input fluence.

36 MATERIALS SCIENCE↗

DOE OSTI2020

System and method for compact adaptive free space optical communications

The present disclosure relates to a free-space optical communications system that may make use of a controller and a digital micro mirror (DMM) assembly in communication with the controller. The DMM may have a plurality of independently controllable micromirror elements forming both an emitter and a receiver. A laser is included which is configured to generate an optical beam which may be applied to select ones of the first subpluralities of micromirror elements to generate a transmitted free space optical signal along a selected vector. A detector is included for receiving an incoming free space optical signal imaged by at least one of the micromirror elements.

42 ENGINEERING↗

DOE OSTI2022

Laser-based ultrasound interrogation of surface and sub-surface features in advanced manufacturing materials

Abstract Structures formed by advanced manufacturing methods increasingly require nondestructive characterization to enable efficient fabrication and to ensure performance targets are met. This is especially important for aerospace, military, and high precision applications. Surface acoustic waves (SAW) generated by laser-based ultrasound can detect surface and sub-surface defects relevant for a broad range of advanced manufacturing processes, including laser powder bed fusion (LPBF). In particular, an all-optical SAW generation and detection configuration can effectively interrogate laser melt lines. Here we report on scattered acoustic energy from melt lines, voids, and surface features. Sub-surface voids are also characterized using X-ray Computed Tomography (CT). High resolution CT results are presented and compared with SAW measurements. Finite difference simulations inform experimental measurements and analysis.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Peening Techniques for Mitigating Chlorine-Induced Stress Corrosion Cracking of Dry Storage Canisters for Nuclear Applications

Fusion-welded austenitic stainless steel (ASS) was predominantly employed to manufacture dry storage canisters (DSCs) for the storage applications of spent nuclear fuel (SNF). However, the ASS weld joints are prone to chloride-induced stress corrosion cracking (CISCC), a critical safety issue in the nuclear industry. DSCs were exposed to a chloride-rich environment during storage, creating CISCC precursors. The CISCC failure leads to nuclear radiation leakage. Therefore, there is a critical need to enhance the CISCC resistance of DSC weld joints using promising repair techniques. This review article encapsulates the current state-of-the-art of peening techniques for mitigating the CISCC in DSCs. More specifically, conventional shot peening (CSP), ultrasonic impact peening (UIP), and laser shock peening (LSP) were elucidated with a focus on CISCC mitigation. The underlying mechanism of CISCC mitigation in each process was summarized. Finally, this review provides recent advances in surface modification techniques, repair techniques, and developments in welding techniques for CISCC mitigation in DSCs.

Chemistry↗

DOE OSTI2024

Atomic order of rare earth ions in a complex oxide: a path to magnetotaxial anisotropy

Abstract Complex oxides offer rich magnetic and electronic behavior intimately tied to the composition and arrangement of cations within the structure. Rare earth iron garnet films exhibit an anisotropy along the growth direction which has long been theorized to originate from the ordering of different cations on the same crystallographic site. Here, we directly demonstrate the three-dimensional ordering of rare earth ions in pulsed laser deposited (Eu x Tm 1-x ) 3 Fe 5 O 12 garnet thin films using both atomically-resolved elemental mapping to visualize cation ordering and X-ray diffraction to detect the resulting order superlattice reflection. We quantify the resulting ordering-induced ‘magnetotaxial’ anisotropy as a function of Eu:Tm ratio using transport measurements, showing an overwhelmingly dominant contribution from magnetotaxial anisotropy that reaches 30 kJ m −3 for garnets with x = 0.5. Control of cation ordering on inequivalent sites provides a strategy to control matter on the atomic level and to engineer the magnetic properties of complex oxides.

Science & Technology - Other Topics↗

DOE OSTI2022

Boiling and cavitation caused by transient heat transfer in superfluid helium-4

Superfluid helium-4 (He II) has been widely utilized as a coolant in various scientific and engineering applications due to its superior heat transfer capability. An important parameter required in the design of many He II based cooling systems is the peak heat flux $q^*$, which refers to the threshold heat flux above which boiling spontaneously occurs in He II. Past experimental and numerical studies showed that $q^*$ increases when the heating time $t_h$ is reduced, which leads to an intuitive expectation that very high $q^*$ may be achievable at sufficiently small $t_h$. Knowledge on how $q^*$ actually behaves at small $t_h$ is important for applications such as laser ablation in He II. Furthermore we present a numerical study on the evolution of the thermodynamic state of the He II in front of a planar heater by solving the He II two-fluid equations of motion. For an applied heat flux, we determine the heating time beyond which the He II near the heater transits to the vapor phase. As such, a curve correlating $q^*$ and $t_h$ can be obtained, which nicely reproduces some relevant experimental data. Surprisingly, we find that there exists a critical peak heat flux $q^*_c$, above which boiling occurs nearly instantaneously regardless of $t_h$. We reveal that the boiling in this regime is essentially cavitation caused by the combined effects of the first-sound and the second-sound waves in He II. Based on this physical picture, an analytical model for $q^*_c$ is developed, which reproduces the simulated $q^*_c$ values at various He II bath temperatures and hydrostatic head pressures. This work represents a major progress in our understanding of transient heat transfer in He II.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2023

Integrated photonic molecule Brillouin laser with a high-power sub-100-mHz fundamental linewidth

Photonic integrated lasers with an ultra-low fundamental linewidth and a high output power are important for precision atomic and quantum applications, high-capacity communications, and fiber sensing, yet wafer-scale solutions have remained elusive. Here we report an integrated stimulated Brillouin laser (SBL), based on a photonic molecule coupled resonator design, that achieves a sub-100-mHz fundamental linewidth with greater than 10-mW output power in the C band, fabricated on a 200-mm silicon nitride (Si 3 N 4 ) CMOS-foundry compatible wafer-scale platform. The photonic molecule design is used to suppress the second-order Stokes (S2) emission, allowing the primary lasing mode to increase with the pump power without phase noise feedback from higher Stokes orders. The nested waveguide resonators have a 184 million intrinsic and 92 million loaded Q, over an order of magnitude improvement over prior photonic molecules, enabling precision resonance splitting of 198 MHz at the S2 frequency. We demonstrate S2-suppressed single-mode SBL with a minimum fundamental linewidth of 71±18 mHz, corresponding to a 23±6-mHz 2 /Hz white-frequency-noise floor, over an order of magnitude lower than prior integrated SBLs, with an ∼11-mW output power and 2.3-mW threshold power. The frequency noise reaches the resonator-intrinsic thermo-refractive noise from 2-kHz to 1-MHz offset. The laser phase noise reaches −155 dBc/Hz at 10-MHz offset. The performance of this chip-scale SBL shows promise not only to improve the reliability and reduce size and cost but also to enable new precision experiments that require the high-speed manipulation, control, and interrogation of atoms and qubits. Realization in the silicon nitride ultra-low loss platform is adaptable to a wide range of wavelengths from the visible to infrared and enables integration with other components for systems-on-chip solutions for a wide range of precision scientific and engineering applications including quantum sensing, gravitometers, atom interferometers, precision metrology, optical atomic clocks, and ultra-low noise microwave generation.

Liu, Kaikai (ORCID:0000000213609646)↗

DOE OSTI2024

Excitation of optically trapped single particles using femtosecond pulses

Excitation from optically trapped particles is examined through laser-induced breakdown spectroscopy following interactions with mJ-level fs pulses. Optical emissions from sub-ng ablation of precisely positioned cupric oxide microparticles are used as a method to spatially resolve laser–particle interactions resulting in excitation. External focusing lenses are often used to change the dynamics of nonlinear self-focusing of fs pulses to form laser filaments or, alternatively, to form very intense air plasmas. Given the significant implications external focusing has on laser propagation and plasma conditions, single-particle emissions are studied with focusing lenses ranging from 50 to 300 mm. It is shown that, while single particles are less excited at longer focal lengths due to limited energy transfer through laser–particle interactions, the cooler plasma results in a lower thermal background to reveal resolved single-shot emission peaks. Furthermore, by developing an understanding in the fundamental interaction that occurs between single particles and fs pulses and filaments, practical improvements can be made for atmospheric remote sensing of low-concentration aerosols.

42 ENGINEERING↗