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At least 937 records · Page 52
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Pulsed Thermal Tomography Nondestructive Examination of Additively Manufactured Reactor Materials (Second Annual Progress Report)

Additive manufacturing (AM) is an emerging method for cost-efficient fabrication of nuclear reactor parts. AM of metallic structures for nuclear energy applications is currently based on laser powder bed fusion (LPBF) process, which can introduce internal material flaws, such as pores and anisotropy. Integrity of AM structures needs to be evaluated nondestructively because material flaws could lead to premature failures due to exposure to high temperature, radiation and corrosive environment in a nuclear reactor. Thermal tomography (TT) provides a capability for non-destructive evaluation of sub-surface defects in arbitrary size structures. Thermal tomography is a computational method for heat diffusion-based imaging of solids, which provides 3D visualization of data from flash thermography measurements. We investigate thermal tomography imaging and nondestructive evaluation of stainless steel and nickel super alloy metallic structures produced with laser powder bed fusion (LPBF) additive manufacturing (AM) process. Metallic structures produced with LPBF contain defects, and there are limited capabilities to evaluate these structures non-destructively. Thermal tomography reconstruction of 3D apparent spatial effusivity provides information about AM structure geometry and internal material flaws. We study performance of thermal tomography in imaging of metallic structures through COMSOL computer simulations of transient heat transfer, and through reconstruction of data obtained from experimental measurements. Reconstruction of internal defects is investigated using a stainless steel 316L specimen with flat bottom hole (FBH) indentations, and Inconel 718 plate produced with laser powder bed fusion (LPBF) method, which contains imprinted hemispherical shape low density regions containing non-sintered metallic powder. The FBH’s have the same sizes as the imprinted defects in the LPBF specimens, but offer better imaging contrast. Thermal tomography reconstructions provide visualizations of internal defects, and allow for estimation of their sizes and locations. Detection sensitivity of TT is limited by noises. We investigate separation of signal from noise in thermography images using several machine learning (ML) methods, including new spatio-temporal blind source separation (STBSS) and spatio-temporal sparse dictionary learning (STSDL) methods. Performance of the ML methods is benchmarked using thermography data obtained from imaging stainless steel 316L and Inconel 718 specimens produced LPBF method with imprinted calibrated porosity defects. The ML methods are ranked by F-score and execution runtime. Finally, we investigate TT of AM stainless steel 316L specimen with imprinted internal porosity defects using relatively low-cost, small form factor infrared (IR) camera based on uncooled micro bolometer detector. Sparse coding related K-means singular value decomposition (SVD) machine learning, image processing algorithms are developed to improve quality of TT images through removal of Additive white Gaussian noise without blurring the images. Following initial qualification of an AM component for deployment in a nuclear reactor, a compact TT can also be used for in-service nondestructive evaluation (NDE). With capability to perform in-service NDE of the AM component lifecycle, TT data can be used for development of a component digital twin.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS2010

Free-Free Transitions in the Presence of Laser Fields at Very Low Incident Electron Energy

We study the free-free transition in electron-hydrogenic systems in ground state in presence of an external laser field at very loud incident energies. The laser field is treated classically while the collision dynamics is treated quantum mechanically. The laser field is chosen to be monochromatic, linearly polarized and homogeneous. The incident electron is considered to be dressed by the laser in a nonperturbative manner by choosing a Volkov wave function for it. The scattering weave function for the electron is solved numerically by taking into account the effect of the electron exchange, short-range as well as of the long-range interactions to get the S and P wave phase shifts while for the higher angular momentum phase shifts the exchange approximation has only been considered. We calculate the laser assisted differential cross sections (LADCS) for the aforesaid free-free transition process for single photon absorption/emission. The laser intensity is chosen to be much less than the atomic field intensity. A strong suppression is noted in the LADCS as compared to the field free (FF) cross sections. Unlike the FF ones, the LADCS exhibit some oscillations having a distinct maximum at a low value of the scattering angle depending on the laser parameters as well as on the incident energies.

Bhatia, A. K.↗
NASA NTRS2009

Free-Free Transitions in the Presence of Laser Fields at Very Low Incident Electron Energy

We study the free-free transition in electron-hydrogenic systems in ground state in presence of an external laser field at very low incident energies. The laser field is treated classically while the collision dynamics is treated quantum mechanically. The laser field is chosen to be monochromatic, linearly polarized and homogeneous. The incident electron is considered to be dressed by the laser in a nonperturbative manner by choosing a Volkov wave function for it The scattering wave function for the electron is solved numerically by taking into account the effect of the electron exchange, short-range as well as of the long-range interactions to get the S and P wave phase shifts while for the higher angular momentum phase shifts, the exchange approximation has only been considered. We calculate the laser-assisted differential cross sections (LADCS) for the aforesaid free-free transition process for single photon absorption/emission. The laser intensity is chosen to be much less than the atomic field intensity. A strong suppression is noted in the LADCS as compared to the field free (FF) cross sections. Unlike the FF ones, the LADCS exhibit some oscillations having a distinct maximum at a low value of the scattering angle depending on the laser parameters as well as on the incident energies.

Bhatia, Anand K.↗
NASA NTRS2014

Computer Modeling of Direct Metal Laser Sintering

A computational approach to modeling direct metal laser sintering (DMLS) additive manufacturing process is presented. The primary application of the model is for determining the temperature history of parts fabricated using DMLS to evaluate residual stresses found in finished pieces and to assess manufacturing process strategies to reduce part slumping. The model utilizes MSC SINDA as a heat transfer solver with imbedded FORTRAN computer code to direct laser motion, apply laser heating as a boundary condition, and simulate the addition of metal powder layers during part fabrication. Model results are compared to available data collected during in situ DMLS part manufacture.

Cross, Matthew↗
DOE OSTI2024

Ultrahigh Performance Metallic Turbine Blades for Extreme Environments

In ULTIMATE Phase-I, The Boeing Company and Alloyed Inc. aimed to produce ultrahigh performance metallic extreme environment turbine blades with a base blade alloy capable of inert operation at 1300C, and a maximum coated blade operating temperature up to 1800C. High-performance structural designs for extreme service conditions place additional demands on the present material capability and can potentially outpace the current state-of-the-art in the alloy design space and metal processing. As a part of exploration and adoption of novel concepts for material maturation, the team explored a series of capable base novel refractory complex concentrated alloy (RCCA) compositions and potential powder enhancements. Advanced manufacturing processes, with a focus on laser powder bed fusion additive manufacturing (AM) and powder metallurgy (PM) approaches, were applied to consolidate new alloys and for near net shape processing of blades from the base RCCA.

Yousefiani, Ali↗
NASA NTRS2005

Portable Airborne Laser System Measures Forest-Canopy Height

(PALS) is a combination of laser ranging, video imaging, positioning, and data-processing subsystems designed for measuring the heights of forest canopies along linear transects from tens to thousands of kilometers long. Unlike prior laser ranging systems designed to serve the same purpose, the PALS is not restricted to use aboard a single aircraft of a specific type: the PALS fits into two large suitcases that can be carried to any convenient location, and the PALS can be installed in almost any local aircraft for hire, thereby making it possible to sample remote forests at relatively low cost. The initial cost and the cost of repairing the PALS are also lower because the PALS hardware consists mostly of commercial off-the-shelf (COTS) units that can easily be replaced in the field. The COTS units include a laser ranging transceiver, a charge-coupled-device camera that images the laser-illuminated targets, a differential Global Positioning System (dGPS) receiver capable of operation within the Wide Area Augmentation System, a video titler, a video cassette recorder (VCR), and a laptop computer equipped with two serial ports. The VCR and computer are powered by batteries; the other units are powered at 12 VDC from the 28-VDC aircraft power system via a low-pass filter and a voltage converter. The dGPS receiver feeds location and time data, at an update rate of 0.5 Hz, to the video titler and the computer. The laser ranging transceiver, operating at a sampling rate of 2 kHz, feeds its serial range and amplitude data stream to the computer. The analog video signal from the CCD camera is fed into the video titler wherein the signal is annotated with position and time information. The titler then forwards the annotated signal to the VCR for recording on 8-mm tapes. The dGPS and laser range and amplitude serial data streams are processed by software that displays the laser trace and the dGPS information as they are fed into the computer, subsamples the laser range and amplitude data, interleaves the subsampled data with the dGPS information, and records the resulting interleaved data stream.

Nelson, Ross↗
NASA NTRSDate not supplied

Composites From in-Situ Consolidation Automated Fiber Placement of Thermoplastics for High-Rate Aircraft Manufacturing

The National Aeronautics and Space Administration (NASA) project Hi-Rate Composites Aircraft Manufacturing (HiCAM) aims to significantly increase commercial aircraft composite structures manufacturing rate. Thermoplastic composites offer attractive solutions to rapid manufacturing due to their ability to be formed and consolidated quickly. NASA has a particular interest in assessing composite structure manufacturing utilizing an in-situ consolidation automated fiber placement (AFP) of thermoplastics (ICAT) process employing current state-of-the-art laser heating systems. Three semi-crystalline polyaryletherketone (PAEK) thermoplastic tape materials were characterized to ascertain the ICAT process parameters. The required laser power settings were determined at Electroimpact, Inc., measuring material temperatures utilizing a forward looking infrared (FLIR) thermal imaging camera and thermocouples. The material temperature, tool temperature, and placement speed were varied for resulting consolidation quality assessment. The resulting temperature data were also utilized to calibrate thermal analysis models under development at NASA. The experimental temperature data confirmed analytical results. The quality of the resulting test panels was evaluated by both non-destructive evaluation as well as destructively by photo-microscopy. The effect on interlaminar strength was determined by short beam strength testing. Test results of carbon fiber laminates fabricated by ICAT using polyetheretherketone (PEEK), polyetherketoneketone (PEKK), and low-melt polyaryletherketone (LM-PAEK) at various placement temperatures and placement speeds are presented.

thermoplastic composites↗
NASA NTRS1993

New methods of generation of ultrashort laser pulses for ranging

To reach the millimeter satellite laser ranging accuracy, the goal for nineties, new laser ranging techniques have to be applied. To increase the laser ranging precision, the application of the ultrashort laser pulses in connection with the new signal detection and processing techniques, is inevitable. The two wavelength laser ranging is one of the ways to measure the atmospheric dispersion to improve the existing atmospheric correction models and hence, to increase the overall system ranging accuracy to the desired value. We are presenting a review of several nonstandard techniques of ultrashort laser pulses generation, which may be utilized for laser ranging: compression of the nanosecond pulses using stimulated Brillouin and Raman backscattering; compression of the mode-locked pulses using Raman backscattering; passive mode-locking technique with nonlinear mirror; and passive mode-locking technique with the negative feedback.

Jelinkova, Helena↗
NASA NTRS2024

Bending Performance of Tungsten Printed Via Laser Powder Bed Fusion With Ceramic Dispersion Modified Powder Feedstock

Additively manufactured tungsten is a candidate refractory material for high-temperature aerospace and nuclear fusion/fission applications. The printability of pure tungsten is challenged by cracking defects arising from the metal’s high brittle-to-ductile transition temperature and low solubility of interstitial impurities. Furthermore, the cast microstructure inherent to the laser powder bed fusion (L-PBF) process has limited strength compared to worked microstructures common in wrought tungsten. Aside from process-related techniques to mitigate defects and increase strength (e.g., heated build chambers, multi-laser systems, low oxygen environmental control, etc.), micro-alloying additions can positively influence tungsten printability and strength. In this work, pure tungsten L-PBF feedstock was modified with 1 wt% additions of ceramic compound nano-powders. Wrought and printed bars were evaluated in four-point bending. Flexural strength and fractography were primary means of comparison to assess the effect of the feedstock modification on printed tungsten mechanical performance.

Additive Manufacturing↗
DOE OSTI2021

Solid Phase Gradient Alloying Method via ShAPE

Alloying has been used to confer desirable properties to various metallic systems since the bronze age. For example, Ni, Mn, and Cr are alloyed into an Fe matrix to make steel, which has improved strength and corrosion resistance (as displayed in Fig. 1). In addition to the type of alloying elements, the amount of alloying elements added into a matrix is also very critical for a material’s mechanical property, physical property, machinability, and cost. Conventionally, new alloys are discovered by combining alloy precursors and elemental constituents into a mixture and melting them together. The solidified product or ingot represents a usually non-homogeneous combination of the chemistry with a microstructure dictated by the physics of solidification. It is time and energy intensive to optimize the alloying amounts via the casting process and hence, economically not conducive to rapid alloy discovery. In addition, the cast microstructure seen in the as-cast ingot is often not the ideal, nor even desired structure for optimized performance. Cast materials often need further processing such as homogenization, annealing, and deformation work put in through rolling, forging, extruding, etc. to have favorable microstructures and properties. A faster method to discover new alloy combinations and evaluate them in their worked or processed form is needed. Recently, Laser Engineered Net Shaping was applied to fabricate gradient compositional material for alloy designing. However, the mechanical properties of this gradient alloy were poor due to the existence of impurities, oxidation and cracks that are inherent in the melt-solidification process. Because of these limitations, we propose to use a solid-phase process (ShAPE) to create bulk materials (extrudates) that vary in composition from one end of the extruded solid to the other. Various manufacturing methods for alloy design including conventional casting method, laser based combinatorial method and current solid phase gradient alloying method are displayed and compared in Fig. 2. ShAPE machine and a schematic of ShAPE process are displayed in Fig. 3. Starting material is processed by a rotating and plunging die to form an extrudate. We are proposing through this methodology to invent a new, bulk-scale combinatorial technique. With this novel technique, alloying element can be dissolved into the matrix with a continued gradient without bulk melting. Formation of inter-metallics and defects originating from melt processing can be avoided. In addition, the ShAPE process creates the mixed alloy chemistry, and meanwhile subjects the material to severe plastic strain, which induces the favorable “worked” microstructure. Products from the ShAPE process can be tested in hardness directly providing a path to rapid evaluation of mechanical properties. The ability to create graded structures using friction stir processing (FSP) has been demonstrated, however using the ShAPE process we believe will lead to much faster and higher fidelity results. When combined with high throughput screening methods of physical, mechanical and microstructural property characterization, efficiency and accuracy of alloy design can be significantly improved.

36 MATERIALS SCIENCE↗
NASA NTRS1989

Optical technology for microwave applications IV; Proceedings of the Meeting, Orlando, FL, Mar. 28, 29, 1989

Among the topics discussed at the meeting are high-speed laser and electrooptical technologies, detectors and detector arrays, microwave delay lines, and photon-microwave interactions. In addition, optical link applications are discussed, along with electronic warfare receivers and acoustooptical signal processing. Emphasis is placed on laser diode technology, direct modulation of laser diodes, external electrooptical laser modulation techniques, and microwave fiber-optic delay lines. Attention is given to such optical link applications as multigigahertz links as well as to signal processing for phased-array antennas and channelized microwave receiver technologies.

Yao, Shi-Kay↗
NASA NTRS1993

Photorefractive Semiconductors and Applications

Photorefractive semiconductors are attractive for information processing, becuase of fast material response, compatibility with semiconductor lasers, and availability of cross polarization diffraction for enhancing signal-to-noise ration. This paper presents recent experimental results on information processing using photorefractive GaAs, InP and CdTe, including image processing with semiconductor lasers.

Photorefractive Semiconductors↗
DOE OSTI2022

Selected Area Deposition of PtC x Nanostructures: Implications for Functional Coatings of 3D Nanoarchitectures

Here, we report that selected area deposition of 3D nanostructures is induced via a pyrolytic laser chemical vapor deposition (CVD) process where selected area heating results from the unique photothermal transport regime that is intrinsic to 3D nanostructures. PtC x composite nanostructures were deposited by focused electron beam-induced deposition (FEBID) and used as 3D templates. Subsequent simultaneous localized delivery of an organometallic PtC x precursor and pulsed 915 nm laser irradiation to the pre-defined nanostructures results in selected area deposition on the FEBID features. Results indicate the ability to initiate the process on sub-diffraction-limit nanoscale features. To elucidate the mechanisms that are operative in the selected area deposition, we analyze the effects of the laser repetition rate, power, and pulse duration. Thermal simulations corroborate that the pseudo-1D thermal transport of the nanostructure geometry coupled with the optical and thermal properties of the nanostructure governs the CVD reaction. The results demonstrated here suggest that controlling the thermal transport in nanomaterial architectures could be a useful means to spatially control localized photothermally stimulated chemical reactions and induce selected area reactions.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Effect of Processing Parameters on Recrystallization During Hot Isostatic Pressing of Stellite-6 Fabricated Using Laser Powder Bed Fusion Technique

Crack-free Stellite-6 alloy was fabricated using the laser powder bed fusion technique equipped with a heating module as the first attempt. Single tracks were printed with a build plate heated to 400 °C to identify the processing window. Based on the melt pool dimensions, two combinations (sample A: 300 W/750 mm/s and sample B: 275 W/1000 mm/s) were identified to print the cubes. The as-printed microstructure comprised FCC-Co dendrites with M7C3 in the interdendritic region. W-rich M6C particles were found in the overlapping regions between the melt pools, matching the Scheil simulations. However, gas pores were observed due to the higher nitrogen and oxygen content of the feedstock requiring hot isostatic pressing (HIP) at 1250 °C and 150 MPa for 2 h. Sample A was partially recrystallized with slightly coarsened M7C3, while sample B underwent complete recrystallization followed by grain growth along with higher coarsening of the M7C3 after HIP. The varying recrystallization behavior can be attributed to the difference in residual stresses and grain aspect ratio in the as-built condition dictated by laser power and scanning speed. The microhardness after HIP was slightly higher than its wrought counterpart, indicating no severe impact of post-processing on the properties of Stellite-6 alloy.

Sridar, Soumya (ORCID:0000000306775408)↗
DOE OSTI2023

Methods for rapid identification of anomalous layers in laser powder bed fusion

In situ process monitoring is a key requirement for increased industry acceptance of powder bed Additive Manufacturing. As sensing technologies increase in maturity, attention must also be given to effective data exploration techniques. These data are often high-resolution and multi-modal, with each build consisting of thousands of layers. Here, in this paper, the authors propose two methods enabling users to rapidly identify layers of interest within a build. Both methods leverage results from deep learning based segmentations of in situ powder bed images. The first method is an unsupervised “reverse layer search” algorithm while the second method uses supervised machine learning.

36 MATERIALS SCIENCE↗
NASA NTRS1976

Optical computing with laser light

Linear and nonlinear optical processing techniques (Fourier transformation, convolution and correlation, arithmetic operations - addition and subtraction with gratings, generalized orthogonal transformations; theta modulation, half-tone screen process, optical feedback) for mathematical computations are reviewed. The use of gratings and computer holograms in addition, subtraction, differentiation, and application of generalized transformations is discussed. Use of nonlinear optical elements with or without optical coherent feedback in such nonlinear operations as taking logarithms and thresholding is described. Applications in hybrid systems incorporating digital computer and optical processor with real-time interface devices, or optical threshold and logic devices for parallel processing to apply digital techniques to optical information are considered.

Lee, S. H.↗
NASA NTRS2002

High Precision Wavelength Monitor for Tunable Laser Systems

A solid-state apparatus for tracking the wavelength of a laser emission has a power splitter that divides the laser emission into at least three equal components. Differing phase shifts are detected and processed to track variations of the laser emission.

Mark E Froggatt↗