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DOE OSTI2025

Microstructure and Mechanical Properties of Scaled Thermally Aged LPBF 316H SS Builds

As part of the US Department of Energy’s Advanced Materials and Manufacturing Technologies program’s mission to accelerate qualification of advanced manufacturing pathways for nuclear applications, laser powder bed fusion (LPBF) 316H stainless steel (SS) has been selected as a model system to develop a rapid code case framework. This effort directly addresses the grand challenges of (1) expanding the limited portfolio of materials currently codified for elevated-temperature nuclear structural service under Section III, Division 5 of the American Society of Mechanical Engineers’ Boiler and Pressure Vessel Code; and (2) significantly reducing qualification timelines that traditionally exceed a decade. The strategic importance of LPBF 316H lies in its immediate industrial relevance, existing data foundation from wrought 316H, and alignment with ongoing code case development for LPBF 316L. Prior work revealed accelerated precipitation of deleterious secondary phases and reduced creep ductility in as-printed LPBF 316H. Building on that prior research, FY 2025 activities focused on establishing an understanding of the key failure mechanisms of crept 316H specimens to aid in code case development and on evaluating stress relief (SR) parameters on the high-temperature performance and thermal aging induced degradation of tensile and fracture behavior in LPBF 316H.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Depth-Resolved X-Ray Nanoimaging of Coherent and Incoherent Energy Transport in Silicon Carbide

Understanding lattice dynamics is crucial for optimizing the process of creating functional structures, such as laser writing of color-center defects. However, existing structural probes have difficulty measuring structural dynamics with submicrometer depth sensitivity. Here, in this study, a depth-resolved ultrafast X-ray nanodiffraction technique is developed to track the lattice dynamics of silicon carbide (SiC) in three dimensions. Upon laser excitation of an aluminum layer that acts as a heat and strain transducer, a specular Bragg peak of SiC shows an overall increase in the X-ray diffraction intensity rather than a peak shift. The relaxation dynamics of the increased intensity are significantly different when probed on and off the Bragg peak. The fast subnanosecond relaxation probed at the maximum of the Bragg peak is a result of the propagation of a coherent strain wave along the depth direction, while a slow relaxation probed at the wings of the Bragg peak reflects a localized incoherent lattice heating. To further visualize these processes, spatiotemporal maps were obtained by scanning the relative position and delay between the laser pump and X-ray probe beams, which capture the propagation of the strain wave, as well as a stationary structural distortion close to the aluminum/SiC interface. These depth-resolved structural measurements disentangle energy dissipation mechanisms in laser-excited SiC, and they open opportunities for finer control of, for example, the formation of optically addressable defect complexes central to quantum information applications.

X-ray nanodiffraction↗

DOE OSTI2020

Terahertz Spectroscopy of Gas Mixtures with Dual Quantum Cascade Laser Frequency Combs

Terahertz laser frequency combs based on quantum cascade lasers provide coherent, broadband, electrically pumped, THz radiation sources for use in future spectroscopic applications. In this work, we explore the feasibility of such lasers in a dual-comb spectroscopy configuration for the detection of multiple molecular samples in the gas phase. The lasers span approximately 180 GHz of optical bandwidth, centered at 3.4 THz, with submilliwatt total optical power. One of the main advantages of dual-comb spectroscopy is its high speed, which opens up the possibility for direct observations of chemical reaction dynamics in the terahertz spectral region. As a proof-of-concept, we recorded continuously evolving spectra from gas mixtures with 1 ms temporal resolution.

42 ENGINEERING↗

DOE OSTI2021

Modelling the complex evaporated gas flow and its impact on particle spattering during laser powder bed fusion

The additive manufacturing (AM) of metals is becoming an increasingly important production process with the potential to replace traditional techniques such as casting. Laser Powder Bed Fusion (LPBF) is used in many applications to print metal parts from powder. The metal powder is heated locally with sufficient laser radiation that the liquid melt easily reaches its boiling temperature, which leads to a metallic vapour jet that can entrain both powder bed particles and molten droplets. The small size of laser-matter interaction site makes a detailed experimental analysis of the process challenging. Synchrotron X-ray imaging experiments are one of the few methods which can capture the dynamic melting and solidification processes. Comparing such experiments with computer simulations of the process is an important approach in order to better understand the manufacturing process and to analyse the influence of process parameters on the evaporated gas jet and the subsequent impact on particle ejection, leading to potentially reduced AM component quality. The melting and solidification of the metal powder is simulated using an Eulerian multiphase approach based on a control volume discretization of powder bed and substrate and a volume of liquid separation from melt and gas phase. The gas phase modelled as an ideal gas reaches velocities up to 100 m/s. Lagrangian particle tracking in the simulation demonstrates that the velocity fields calculated by the Eulerian multi-phase approach in combination with a standard drag-force model lead to particle accelerations in good agreement with those measured experimentally. In order to avoid numerical laborious Lagrangian calculations, a direct method to compare an Eulerian multiphase simulation with synchrotron X-ray experiments was introduced and validated. This approach is used to analyse the influence of process parameters including laser power and laser speed on the maximal acceleration of particles from the melt pool area. While the particle acceleration increases linearly with line energy in the conduction mode, a linear decrease of the acceleration with increasing line energy can be found in the transition mode before the accel-eration increases again with line energy in the keyhole mode.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Effects of non-equilibrium ionization and excitation on radiation absorption in plasma plumes induced by ablation of metal targets with nanosecond laser pulses

Ionization and radiation absorption in nanosecond laser-induced plasma plumes are routinely modeled using the Saha–Boltzmann equilibrium ionization model (EQM). However, the equilibrium assumption can be inaccurate during the laser pulse when non-equilibrium effects significantly impact radiation absorption. In the present work, the EQM and non-equilibrium collisional-radiative model (CRM) are compared to reveal the effect of plasma non-equilibrium on radiation absorption in non-homogeneous plumes and degree of plasma shielding. Simulations of plume expansion induced by irradiation of a copper target in 1 atm argon background gas with a 10 ns Gaussian pulse at a fluence from 8 Jcm −2 to 14 Jcm −2 are performed with a hybrid computational model that couples a lumped particle direct simulation Monte Carlo method with either CRM or EQM. The simulations show that the EQM strongly underestimates the effects of ionization and radiation absorption compared to CRM and, contrary to the CRM, predict strong ionization of the background gas. The differences between the models are explained by the qualitatively different coupling between plume expansion and dynamics of ionization and exitation processes in the CRM and EQM under conditions when the characteristic times for most radiation- and electron-induced processes are longer than the pulse duration. The CRM-based predictions are also found to agree much better with available experimental data. In conclusion, these results indicate that the model of Saha–Boltzmann equilibrium cannot be used for reliable prediction of the degree of plasma shielding in plumes induced by nanosecond laser pulses or for processing results of spectroscopic measurements at early stages of expansion of such plumes.

Physics - Plasma physics↗

DOE OSTI2025

Ponderomotive electron physics captured in a single-fluid extended magnetohydrodynamics model

The ponderomotive force, arising from the interaction between electromagnetic waves and plasma, plays a critical role in laser fusion, astrophysical plasmas, and laser diagnostics. Traditionally, modeling this force requires multi-fluid or particle-in-cell simulations due to its strong coupling to electron-scale dynamics. In this work, we demonstrate that a one-fluid, two-temperature extended magnetohydrodynamics (XMHD) model—augmented with a generalized Ohm's law (GOL) including electron inertia—can accurately reproduce key ponderomotive effects. We derive the ponderomotive force within this framework using a phasor-based approach and then validate its nonlinear manifestations through direct numerical simulations in the PERSEUS code, where steepening and density modulation phenomena typically associated with kinetic-scale models are reproduced. These results and prior work establish XMHD as a robust and efficient alternative for modeling nonlinear laser–plasma dynamics, bridging the gap between ideal MHD and fully kinetic approaches.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2020

Interface velocity dependent solute trapping and phase selection during rapid solidification of laser melted hypo-eutectic Al-11at.%Cu alloy

Microstructure formation of a hypo-eutectic Al-11Cu (atom percent) alloy during solidification after laser melting has been studied by transmission electron microscopy (TEM). The evolution of the solid-liquid-interface velocity, V SL , during the solidification process has been determined from direct observation by in-situ TEM. This enabled correlating V SL with development of four distinct microstructure zones. Crystal growth mode transitions from planar to cellular, cellular to dendritic, dendritic to cellular, and cellular to planar, have been observed for the accelerating solid-liquid-interface. The transition from coupled two-phase growth to the single-phase growth occurred for V SL = V a = (0.80±0.05) m/s, where V a is the velocity of absolute stability, at the onset of banded morphology grain formation. The in-situ and post-mortem TEM uniquely permitted determination of the non-equilibrium solidus for the rapidly solidifying Al-11Cu alloy. Experimental evidence for solute clustering and chemical ordering tendencies at length scales on the order of ≤ 5nm has been detected in the single-phase regions of the banded grains. The structural features of the single-phase bands have been interpreted as signatures of ‘frozen in’ configurations present in the liquid boundary layer adjacent to the growing crystal, which has a width of about 3nm. Finally, the nano-scale spatiotemporal resolution experimental TEM studies performed here provided quantitative metrics, e.g. the solidification interface velocity dependent solute concentration of the α-Al phase and the near-atomic scale structure in the single-phase bands, that are uniquely suitable for comparison with theory and model predictions for solidification microstructure development in multicomponent alloys after laser melting.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Optically controlling the competition between spin flips and intersite spin transfer in a Heusler half-metal on sub–100-fs time scales

The direct manipulation of spins via light may provide a path toward ultrafast energy-efficient devices. However, distinguishing the microscopic processes that can occur during ultrafast laser excitation in magnetic alloys is challenging. Here, we study the Heusler compound Co 2 MnGa, a material that exhibits very strong light-induced spin transfers across the entire M-edge. By combining the element specificity of extreme ultraviolet high-harmonic probes with time-dependent density functional theory, we disentangle the competition between three ultrafast light-induced processes that occur in Co 2 MnGa: same-site Co-Co spin transfer, intersite Co-Mn spin transfer, and ultrafast spin flips mediated by spin-orbit coupling. By measuring the dynamic magnetic asymmetry across the entire M-edges of the two magnetic sublattices involved, we uncover the relative dominance of these processes at different probe energy regions and times during the laser pulse. Our combined approach enables a comprehensive microscopic interpretation of laser-induced magnetization dynamics on time scales shorter than 100 femtoseconds.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Coupling Pulse Radiolysis with Nanosecond Time-Resolved Step-Scan Fourier Transform Infrared Spectroscopy: Broadband Mid-Infrared Detection of Radiolytically Generated Transients

We describe the first implementation of broadband, nanosecond time-resolved step-scan Fourier transform infrared (S 2 -FT-IR) spectroscopy at a pulse radiolysis facility. This new technique allows the rapid acquisition of nano- to microsecond time-resolved infrared (TRIR) spectra of transient species generated by pulse radiolysis of liquid samples at a pulsed electron accelerator. Wide regions of the mid-infrared can be probed in a single experiment, which often takes < 20–30 min to complete. It is therefore a powerful method for rapidly locating the IR absorptions of short-lived, radiation-induced species in solution, and for directly monitoring their subsequent reactions. Time-resolved step-scan FT-IR detection for pulse radiolysis thus complements our existing narrowband quantum cascade laser-based pulse radiolysis-TRIR detection system, which is more suitable for acquiring single-shot kinetics and narrowband TRIR spectra on small-volume samples and in strongly absorbing solvents, such as water. We have demonstrated the application of time-resolved step-scan FT-IR spectroscopy to pulse radiolysis by probing the metal carbonyl and organic carbonyl vibrations of the one-electron-reduced forms of two Re-based CO 2 reduction catalysts in acetonitrile solution. Transient IR absorption bands with amplitudes on the order of 1 × 10 −3 are easily detected on the sub-microsecond timescale using electron pulses as short as 250 ns.

(S2-FT-IR)↗

DOE OSTI2020

Housedon-Hill - A ChemCam/RMI mega mosaic to investigate distant features

The ChemCam Remote Microscopic Imager (RMI) onboard Curiosity was originally designed to document the tiny areas analyzed by ChemCam’s laser-induced breakdown spectroscopy (LIBS) technique on rocks at few meters distance around the rover. The RMI produces 1024 x 1024 pixel black and white images directly from ChemCam’s telescope focal plane. Early in the mission, it was recognized that, thanks to its powerful optics, RMI could also play a role as a long-distance reconnaissance tool, complementing other cameras on the remote sensing mast, and taking advantage of its very long 700 mm focal length. Imaging areas several kilometers from the rover provides pictures that are very complementary to orbital observations and gives a more human-like, ground-based perspective. Between sols 2878 and 2921, Curiosity stayed parked at the same place to perform various rock sampling analyses. This opportunity was used to target very distant areas of interest, daily building an RMI mosaic of 216 overlapping images covering an area ranging from the bottom layers of Mount Sharp to the edge of Vera Rubin Ridge. This product is so far the largest RMI mosaic acquired during the entire mission.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2023

Development of an accelerated creep testing technique via multi-specimen loading

This report summarizes a research effort undertaken by Argonne National Laboratory to accelerate the development of creep data package for code qualification. The goal is to explore new creep testing techniques to shorten the overall time needed to generate high-quality data to support an ASME code case on laser powder bed fusion 316H stainless steel. Progresses on the design and implementation of a 3-specimen load train and an innovative strain measurement method with direct potential current drop (DCPD) technique are reported.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2021

System and method for laser system having non-planar thin disc gain media

The present disclosure relates to a laser system. The laser system may have at least non-flat gain media disc. At least one pump source may be configured to generate a beam that pumps the non-flat gain media disc. A laser cavity may be formed by the pump source and the non-flat gain media disc. An output coupler may be included for receiving and directing the output beam toward an external component.

Dawson, Jay W.↗

DOE OSTI2022

Optimization of stochastic feature properties in laser powder bed fusion

Process parameter selection in laser powder bed fusion (LPBF) controls the as-printed dimensional tolerances, pore formation, surface quality and microstructure of printed metallic structures. Measuring the stochastic mechanical performance for a wide range of process parameters is cumbersome both in time and cost. As such, in this study, we overcome these hurdles by using high-throughput tensile (HTT) testing of over 250 dogbone samples to examine process-driven performance of strut-like small features, ~1 mm 2 in austenitic stainless steel (316 L). The output mechanical properties, porosity, surface roughness and dimensional accuracy were mapped across the printable range of laser powers and scan speeds using a continuous wave laser LPBF machine. Tradeoffs between ductility and strength are shown across the process space and their implications are discussed. While volumetric energy density deposited onto a substrate to create a melt-pool can be a useful metric for determining bulk properties, it was not found to directly correlate with output small feature performance.

316 L stainless steel↗

DOE OSTI2025

X-ray free-electron lasing in a flying-focus undulator

Laser-driven free-electron lasers (LDFELs) replace magnetostatic undulators with the electromagnetic fields of a laser pulse. Because the undulator period is half the wavelength of the laser pulse, LDFELs can amplify X rays using lower electron energies and over shorter interaction lengths than a traditional free-electron laser. In LDFELs driven by conventional laser pulses, the undulator uniformity required for high gain necessitates large laser-pulse energies. Here, we show that a flying-focus pulse provides the undulator uniformity required to reach high gain with a substantially lower energy than a conventional pulse. The flying-focus pulse features an intensity peak that travels in the opposite direction of its phase fronts. This enables an LDFEL configuration where an electron beam collides head-on with the phase fronts and experiences a near-constant undulator strength as it co-propagates with the intensity peak. Three-dimensional simulations of this configuration demonstrate the generation of megawatts of coherent X-ray radiation with 20 × less energy than a conventional laser pulse.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2025

Photoionization of seeded combustion products as a method of enhancing the efficiency of magnetohydrodynamic power generators

Here, in this study, we performed an experimental and computational investigation into the feasibility of utilizing photoionization to enhance the electrical conductivity of seeded oxy-fuel combustion products and improve the performance of magnetohydrodynamic (MHD) power generators. We applied a variety of optical and microwave diagnostics to study the ionization and recombination processes of potassium excited by an excimer laser in a high-velocity oxy-fuel free jet. Computational fluid dynamic (CFD) simulations were performed to model the thermophysical properties and species densities of the free jet. The CFD results were validated with position-dependent potassium concentration measurements. Electron recombination exponential lifetimes were measured through time-resolved microwave transmission. The experimental electron lifetimes were compared with lifetimes calculated from CFD-predicted species densities and literature recombination rates. It was determined that K + or O 2 are the most likely recombination partners for photoionized electrons. Time-resolved fluorescence measurements provided evidence of an ionization pathway involving a two-photon ionization of KOH . Finally, a zero-dimensional chemical kinetic model was developed to assess the fundamental viability of inducing a non-equilibrium electron population to provide a net energy return in combustion-driven MHD power generators. We determined that a high energy return is feasible for targeting electrode boundary layers with ultraviolet photoionization. We also found that photoionization could potentially lower the required temperature of the bulk gas flow.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2022

Microdroplet Electrospray Localized Laser Printing and Sintering of Nanoparticles for Passivating, Carrier-Selective Contacts (Final Technical Report)

In this project, the team used a nanoparticle electrospray laser deposition (NELD) process developed at the University of Central Florida (UCF) to address current limitations of passivating, carrier-selective contact technologies for crystalline silicon (c-Si) photovoltaic (PV) cells. The NELD process was used to print low bulk line resistivity Ag contacts directly onto transparent conductive oxides (TCOs), like indium tin oxide (ITO), for hydrogenated amorphous silicon (a-Si:H) based c-Si heterojunction (SHJ) cells without any subsequent contact firing step needed.

14 SOLAR ENERGY↗

DOE OSTI2022

Fabricating Graphene Oxide/h-BN Metal Insulator Semiconductor Diodes by Nanosecond Laser Irradiation

To employ graphene’s rapid conduction in 2D devices, a heterostructure with a broad bandgap dielectric that is free of traps is required. Within this paradigm, h-BN is a good candidate because of its graphene-like structure and ultrawide bandgap. We show how to make such a heterostructure by irradiating alternating layers of a-C and a-BN film with a nanosecond excimer laser, melting and zone-refining constituent layers in the process. With Raman spectroscopy and ToF-SIMS analyses, we demonstrate this localized zone-refining into phase-pure h-BN and rGO films with distinct Raman vibrational modes and SIMS profile flattening after laser irradiation. Furthermore, in comparing laser-irradiated rGO-Si MS and rGO/h-BN/Si MIS diodes, the MIS diodes exhibit an increased turn-on voltage (4.4 V) and low leakage current. The MIS diode I-V characteristics reveal direct tunneling conduction under low bias and Fowler-Nordheim tunneling in the high-voltage regime, turning the MIS diode ON with improved rectification and current flow. This study sheds light on the nonequilibrium approaches to engineering h-BN and graphene heterostructures for ultrathin field effect transistor device development.

2D materials↗

DOE OSTI2021

Ultra-short pulse generation from mid-IR to THz range using plasma wakes and relativistic ionization fronts

In this work, we discuss numerical and experimental results on frequency downshifting and upshifting of a 10 μ m infrared (IR) laser to cover the entire wavelength (frequency) range from λ = 1 to 150 μ m ( ν = 300–2 THz) using two different plasma techniques. The first plasma technique utilizes frequency downshifting of the drive laser pulse in a nonlinear plasma wake. Based on this technique, we have proposed and demonstrated that in a tailored plasma structure, multi-millijoule energy, single-cycle, long-wavelength IR (3–20 μ m) pulses can be generated by using an 810 nm Ti:sapphire drive laser. Here, we extend this idea to the THz frequency regime. We show that sub-joule, terawatts, single-cycle terahertz (2–12 THz or 150–25 μ m) pulses can be generated by replacing the drive laser with a picosecond 10 μ m CO 2 laser and a different shaped plasma structure. The second plasma technique employs frequency upshifting by colliding a CO 2 laser with a rather sharp relativistic ionization front created by ionization of a gas in less than half cycle (17 fs) of the CO 2 laser. Even though the electrons in the ionization front carry no energy, the frequency of the CO 2 laser can be upshifted due to the relativistic Doppler effect as the CO 2 laser pulse enters the front. The wavelength can be tuned from 1 to 10 μ m by simply changing the electron density of the front. While the upshifted light with 5 < λ ( μ m ) < 10 propagates in the forward direction, that with 1 < λ ( μ m ) < 5 is back-reflected. These two plasma techniques seem extremely promising for covering the entire molecular fingerprint region.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗