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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 955 records · Page 53
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Evolution of global and local deformation in additively manufactured octet truss lattice structures

Additively manufactured lattice truss structures, often referred to as architected cellular materials, present significant advantages over conventional structures due to their unique characteristics such as high strength-to-weight ratios and surface area-to-volume ratios. These geometrically complex structures, however, come with concomitant challenges for qualification and inspection. In this study, compression testing interrupted with micro-computed tomography inspection was conducted to monitor the evolution of global and local deformation throughout the loading process of 304L stainless steel octet truss lattice structures. Both two- and three-dimensional image analysis techniques were leveraged to characterize geometric heterogeneities resulting from the laser powder bed fusion manufacturing process as well as track the structure throughout deformation. Variations from model-predicted behavior resulting from these heterogeneities are considered relative to the predicted and actual responses of the structures during compression to better understand, model, and predict the octet truss lattice structure compression response.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Epitaxially crystallized polyethylene exhibiting near‐equilibrium melting temperatures*

Abstract The morphology and orientation of polymer crystals are important factors which determine the performance of thin‐film, polymer‐based technologies such as organic electronic devices and gas separation membranes. Here, we utilize polymer‐substrate epitaxy to achieve a highly oriented crystalline morphology during thin‐film processing. To accomplish this, we employ matrix‐assisted pulsed laser evaporation (MAPLE), a slow physical vapor deposition process, to deposit linear polyethylene epitaxially atop a graphene substrate. Via MAPLE, we demonstrate the ability to achieve a film morphology comprised of well‐aligned, edge‐on crystalline lamellae. Furthermore, we show that MAPLE can be exploited to grow crystalline lamellae composed entirely of extended polymer chains which exhibit a near‐equilibrium melting temperature. Our study demonstrates that MAPLE, as a bottom‐up approach, can deposit polymer thin films with improved control over crystalline morphology.

Wang, Yucheng↗
NASA NTRS1972

Simple technique for sequential Q-switching of molecular lasers.

A simple technique for sequentially Q-switching molecular lasers is discussed in which an optical scanner is used as an optical folding element in a laser cavity consisting of a stationary diffraction grating and partially reflecting mirror. Sequential Q-switching of a conventional CO2 laser is demonstrated in which over sixty-two transitions between 9.2 and 10.8 microns are observed. Rapid repetition rates (200 Hz) and narrow laser pulses (less than 5 microsec) allow conventional signal processing techniques to be used with this multiwavelength laser source which is a versatile tool for laser propagation studies, absorption spectroscopy, and gain measurements. Results of a preliminary experiment demonstrating the utility of measuring selective absorption of CO2 laser wavelengths by C2H4 are shown.

Lucht, R. A.↗
DOE OSTI2021

Lasergate: A windowless gas target for enhanced laser preheat in magnetized liner inertial fusion

At the Z Facility at Sandia National Laboratories, the magnetized liner inertial fusion (MagLIF) program aims to study the inertial confinement fusion in deuterium-filled gas cells by implementing a three-step process on the fuel: premagnetization, laser preheat, and Z-pinch compression. In the laser preheat stage, the Z-Beamlet laser focuses through a thin polyimide window to enter the gas cell and heat the fusion fuel. However, it is known that the presence of the few μm thick window reduces the amount of laser energy that enters the gas and causes window material to mix into the fuel. These effects are detrimental to achieving fusion; therefore, a windowless target is desired. The Lasergate concept is designed to accomplish this by “cutting” the window and allowing the interior gas pressure to push the window material out of the beam path just before the heating laser arrives. In this work, we present the proof-of-principle experiments to evaluate a laser-cutting approach to Lasergate and explore the subsequent window and gas dynamics. Further, an experimental comparison of gas preheat with and without Lasergate gives clear indications of an energy deposition advantage using the Lasergate concept, as well as other observed and hypothesized benefits. While Lasergate was conceived with MagLIF in mind, the method is applicable to any laser or diagnostic application requiring direct line of sight to the interior of gas cell targets.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

Few-femtosecond resolved imaging of laser-driven nanoplasma expansion

Abstract The free expansion of a planar plasma surface is a fundamental non-equilibrium process relevant for various fields but as-yet experimentally still difficult to capture. The significance of the associated spatiotemporal plasma motion ranges from astrophysics and controlled fusion to laser machining, surface high-harmonic generation, plasma mirrors, and laser-driven particle acceleration. Here, we show that x-ray coherent diffractive imaging can surpass existing approaches and enables the quantitative real-time analysis of the sudden free expansion of laser-heated nanoplasmas. For laser-ionized SiO 2 nanospheres, we resolve the formation of the emerging nearly self-similar plasma profile evolution and expose the so far inaccessible shell-wise expansion dynamics including the associated startup delay and rarefaction front velocity. Our results establish time-resolved diffractive imaging as an accurate quantitative diagnostic platform for tracing and characterizing plasma expansion and indicate the possibility to resolve various laser-driven processes including shock formation and wave-breaking phenomena with unprecedented resolution.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Laser-induced slip casting as an additive manufacturing approach for silicon carbide

Here, this work presents processing silicon carbide (SiC) with the laser-induced slip casting (LIS) additive manufacturing (AM). SiC was stabilized in water with polyethyleneimine (PEI) dispersant, and SiC slurries were made with rheology for LIS printing. High-density ceramic parts were printed, followed by single-step binder burnout and sintering. The printed parts achieved 93–95 % of theoretical density. X-ray computed tomography (XCT) revealed a small distribution of flaws exceeding 100 microns. The mechanical properties were measured in both parallel and perpendicular to the printing layers, and the orientation with layers perpendicular to the bending moment resulted in higher strength compared to the parallel direction. Porosity resulting from processing and large inclusions of boron carbide (B4C) were the root cause of failure in the measured samples. Despite these defects through this effort, this new approach demonstrates promise for green forming of SiC with densities greater than 95 % theoretical and tensile strengths above 250 MPa.

Additive Manufacturing↗
NASA NTRS1989

Laser applications in meteorology and earth and atmospheric remote sensing; Proceedings of the Meeting, Los Angeles, CA, Jan. 16-18, 1989

Various papers on laser applications in meteorology and earth and atmospheric remote sensing are presented. The individual topics addressed include: solid state lasers for the mid-IR region, tunable chromium lasers, GaInAsSb/AlGaAsSb injection lasers for remote sensing applications, development and design of an airborne autonomous wavemeter for laser tuning, fabrication of lightweight Si/SiC lidar mirrors, low-cost double heterostructure and quantum-well laser array development, nonlinear optical processes for the mid-IR region, simulated space-based Doppler lidar performance in regions of backscatter inhomogeneities, design of CO2 recombination catalysts for closed-cycle CO2 lasers, density measurements with combined Raman-Rayleigh lidar, geodynamics applications of spaceborne laser ranging, use of aircraft laser ranging data for forest mensuration, remote active spectrometer, multiwavelngth and triple CO2 lidars for trace gas detection, analysis of laser diagnostics in plumes, laser atmospheric wind sounder, compact Doppler lidar system using commercial off-the-shelf components, and preliminary design for a laser atmospheric wind sounder.

Sokoloski, Martin M.↗
DOE OSTI2024

Atmosphere Effects in Laser Powder Bed Fusion: A Review

The use of components fabricated by laser powder bed fusion (LPBF) requires the development of processing parameters that can produce high-quality material. Manipulating the most commonly identified critical build parameters (e.g., laser power, laser scan speed, and layer thickness) on LPBF equipment can generate acceptable parts for established materials and moderately intricate part geometries. The need to fabricate increasingly complex parts from unique materials drives the limited research into LPBF process control using underutilized parameters, such as atmosphere composition and pressure. As presented in this review, manipulating atmosphere composition and pressure in laser beam welding has been shown to expand processing windows and produce higher-quality welds. The similarities between laser beam welding and laser-based AM processes suggest that this atmosphere control research could be effectively adapted for LPBF, an area that has not been widely explored. Tailoring this research for LPBF has significant potential to reveal novel processing regimes. This review presents the current state of the art in atmosphere research for laser beam welding and LPBF, with a focus on studies exploring cover gas composition and pressure, and concludes with an outlook on future LPBF atmosphere control systems.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS1989

Laser power transmission concepts for Martian applications

Long-term, highly reliable, flexible power will be required to support many diverse activities on Mars and for rapid development of the Mars environment. The potential of laser power transmission for supporting science, materials processing, transportation, and human habitats is discussed. Some advantageous locations for laser power stations in Mars orbit are developed.

De Young, R. J.↗
DOE OSTI2022

Predicting defects in laser powder bed fusion using in-situ thermal imaging data and machine learning

Variation in the local thermal history during the Laser Powder Bed Fusion (LPBF) process in Additive Manufacturing (AM) can cause micropore defects, which add to the uncertainty of the mechanical properties (e.g., fatigue life, tensile strength) of the built materials. In-situ sensing has been proposed for monitoring the AM process to minimize defects, but successful minimization requires establishing a quantitative relationship between the sensing data and the porosity, which is particularly challenging with a large number of variables (e.g., laser speed, power, scan path, powder property). Physics-based modeling can simulate such an in-situ sensing-porosity relationship, but it is computationally costly. In this work, we develop Machine Learning (ML) models that can use in-situ thermographic data to predict the micropore of LPBF stainless steel materials. This work considers two identified key features from the thermal histories: the time above the apparent melting threshold ($\tau$) and the maximum radiance ( T max ). These features are computed, stored for each voxel in the built material, and then used as inputs. The binary state of each voxel, either defective or normal, is the output. Different ML models are trained and tested for the binary classification task. In addition to using the thermal features of each voxel to predict its own state, the thermal features of neighboring voxels are also included as inputs. This is shown to improve the prediction accuracy, which is consistent with thermal transport physics around each voxel contributing to its final state. Among the models trained, the F1 scores on test sets reach above 0.96 for Random Forests. Feature importance analysis based on the ML models shows that T max is more important to the voxel state than $\tau$ . The analysis also finds that the thermal history of the voxels above the present voxel is more influential than those beneath it. Our study significantly extends the capability of using in-situ thermographic data to predict porosity in LPBF materials. Finally, since ML models are fast, they may play integral roles in the optimization and control of such AM technologies.

36 MATERIALS SCIENCE↗
NASA NTRS2021

ICESat-2 Constraint Analysis and Monitoring System (CAMS)

The Ice, Cloud and land Elevation Satellite-2 was launched on 15 September 2018 with mission goals of collecting surface elevation data that can precisely measure ice sheet topography, cloud and aerosol heights, land topography, as well as vegetation height for ecosystems studies. The Constraint Analysis and Monitoring System (CAMS) was implemented as an ICESat-2 ground system element to perform Mission Planning and Spacecraft Safety Monitoring. Mission Planning requires CAMS to serve as an interface between the Project Science Office, the Instrument Support Facility and the Mission Operation Control Center. By ingesting inputs received from all three groups, the CAMS builds an optimized and deconflicted timeline of science and instrument activities. Based upon the timeline of activities, the CAMS utilizes a sophisticated set of algorithms to model and predict the location and pointing of the spacecraft instrument relative to the Earth and Sun. From the predicted position and pointing, the CAMS provides precise monitoring of instrument health, and performs space asset laser conjunction detection. Furthermore, the CAMS determines alternative plans to prevent detected health constraint violations or mitigate potential laser conjunctions. This paper provides an overview of the CAMS and presents the operational performance of planning science and instrument activities, the monitoring of instrument constraints for health and safety, and the space asset laser conjunction screening and mitigation process.

ICESat-2↗
DOE OSTI2022

Characterization of Refractory Alloys Produced by Laser Additive Manufacturing

Refractory alloys often possess superior thermomechanical properties compared to conventional materials, such as steels, Ni-based superalloys, and Ti alloys, especially in high-temperature environments. While these materials promise to revolutionize numerous industries, significant hurdles remain for insertion into applications due to an incomplete understanding of structure-property relationships and conventional processing challenges. We explore laser-based additive manufacturing (AM) to construct refractory alloys consisting of combinations of Mo, Nb, Ta, and Ti with systematically increasing compositional complexity. Microstructure, composition, and hardness of the AM-processed alloys were characterized. Results are discussed in the context of pairing additive manufacturing with refractory metals to enable next-generation alloys.

Kustas, Andrew B.↗
DOE OSTI2020

A Digital Twin Approach to Study Additive Manufacturing Processing Using Embedded Optical Fiber Sensors and Numerical Modeling

One of the major challenges for metal-powder-based additive manufacturing is measuring and mitigating residual strain induced during the manufacturing processes. This article reports distributed fiber optic sensors embedded in Inconel alloy components as experimental means to validate numerical models of additive manufacturing process. Electroplating was used to deposit a metal protective jacket onto standard telecom single-mode fibers for strain measurements, Fiber sensors were embedded in an Inconel alloy substrate using the laser engineered net shaping (LENS) process. Here by using a Rayleigh-scattering optical frequency domain reflectometer (OFDR), temperature changes, and residual strain in the metal substrate were monitored with 5 mm spatial resolution during the LENS process. Using finite element analysis, temperature and strain profiles induced by the LENS deposition processes were also numerically studied. Discrepancies between the simulated temperature and strain profiles and those measured directly were less than 10%. Results presented in this article demonstrates a digital twin approach to fuse modeling results with distributed fiber sensor measurement data to study additive manufacturing process toward design and fabrication process optimization.

36 MATERIALS SCIENCE↗
NASA NTRS2014

Fourier Transform Spectrometer System

A Fourier transform spectrometer (FTS) data acquisition system includes an FTS spectrometer that receives a spectral signal and a laser signal. The system further includes a wideband detector, which is in communication with the FTS spectrometer and receives the spectral signal and laser signal from the FTS spectrometer. The wideband detector produces a composite signal comprising the laser signal and the spectral signal. The system further comprises a converter in communication with the wideband detector to receive and digitize the composite signal. The system further includes a signal processing unit that receives the composite signal from the converter. The signal processing unit further filters the laser signal and the spectral signal from the composite signal and demodulates the laser signal, to produce velocity corrected spectral data.

Campbell, Joel F.↗
NASA NTRS2000

Growth of Carbon Nanostructure Materials Using Laser Vaporization

Since the potential applications of carbon nanotubes (CNT) was discovered in many fields, such as non-structure electronics, lightweight composite structure, and drug delivery, CNT has been grown by many techniques in which high yield single wall CNT has been produced by physical processes including arc vaporization and laser vaporization. In this presentation, the growth mechanism of the carbon nanostructure materials by laser vaporization is to be discussed. Carbon nanoparticles and nanotubes have been synthesized using pulsed laser vaporization on Si substrates in various temperatures and pressures. Two kinds of targets were used to grow the nanostructure materials. One was a pure graphite target and the other one contained Ni and Co catalysts. The growth temperatures were 600-1000 C and the pressures varied from several torr to 500 torr. Carbon nanoparticles were observed when a graphite target was used, although catalysts were deposited on substrates before growing carbon films. When the target contains catalysts, carbon nanotubes (CNT) are obtained. The CNT were characterized by scanning electron microscopy, x-ray diffraction, optical absorption and transmission, and Raman spectroscopy. The temperature-and pressure-dependencies of carbon nanotubes' growth rate and size were investigated.

Zhu, Shen↗
NASA NTRS1986

Resonance ionization mass spectrometry for isotopic abundance measurements

Resonance ionization mass spectrometry (RIMS) is a relatively new laser-based technique for the determination of isotopic abundances. The resonance ionization process depends upon the stepwise absorption of photons from the laser, promoting atoms of the element of interest through progressively higher electronic states until an ion is formed. Sensitivity arises from the efficiency of the resonant absorption process when coupled with the power available from commercial laser sources. Selectivity derives naturally from the distinct electronic structure of different elements. This isobaric discrimination has provided the major impetus for development of the technique. Resonance ionization mass spectrometry was used for analysis of the isotopic abundances of the rare earth lutetium. Isobaric interferences from ytterbium severely effect the ability to measure small amounts of the neutron-deficient Lu isotopes by conventional mass spectrometric techniques. Resonance ionization for lutetium is performed using a continuous-wave laser operating at 452 nm, through a sequential two-photon process, with one photon exciting the intermediate resonance and the second photon causing ionization. Ion yields for microgram-sized quantities of lutetium lie between 10(6) and 10(7) ions per second, at overall ionization efficiencies approaching 10(-4). Discrimination factors against ytterbium greater than 10(6) have been measured. Resonance ionization for technetium is also being explored, again in response to an isobaric interference, molybdenum. Because of the relatively high ionization potential for Tc, three-photon, two-color RIMS processes are being developed.

Miller, C. M.↗
DOE OSTI2023

Optically Excited Lasing in a Cavity‐Based, High‐Current‐Density Quantum Dot Electroluminescent Device

Abstract Laser diodes based on solution‐processable materials can benefit numerous technologies including integrated electronics and photonics, telecommunications, and medical diagnostics. An attractive system for implementing these devices is colloidal semiconductor quantum dots (QDs). The progress towards a QD laser diode has been hampered by rapid nonradiative Auger decay of optical‐gain‐active multicarrier states, fast device degradation at high current densities required for laser action, and unfavorable competition between optical gain and optical losses in a multicomponent device stack. Here we resolve some of these challenges and demonstrate optically excited lasing from fully functional high‐current density electroluminescent (EL) devices with an integrated optical resonator. This advance has become possible due to excellent optical gain properties of continuously graded QDs and a refined device architecture, which allows for highly efficient light amplification in a thin, EL‐active QD layer.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Frequency domain measurements of melt pool recoil force using modal analysis

Recoil pressure is a critical factor affecting the melt pool dynamics during Laser Powder Bed Fusion (LPBF) processes. Recoil pressure depresses the melt pool. When the recoil pressure is low, thermal conduction and capillary forces may be inadequate to provide proper fusion between layers. However, excessive recoil pressure can produce a keyhole inside the melt pool, which is associated with gas porosity. Direct recoil pressure measurements are challenging because it is localized over an area proportionate to the laser spot size producing a force in the mN range. This paper reports a vibrationbased approach to quantify the recoil force exerted on a part in a commercial LPBF machine. The measured recoil force is consistent with estimates from high speed synchrotron imaging of entrained particles, and the results show that the recoil force scales with applied laser power and is inversely related to the laser scan speed. These results facilitate further studies of melt pool dynamics and have the potential to aid process development for new materials.

42 ENGINEERING↗