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DOE OSTI2025

Inkless, dry printing nanographene via in-Situ Coordinated laser ablation and sintering processes

Printing carbon, such as graphene and other carbon structures, for flexible and printed electronics currently relies on either ink-based printing, laser-induced forward transfer (LIFT), or laser-induced graphitization (LIG) to convert carbon-rich precursor materials, such as polymers, to graphene-like carbon structures. Liquid inks contain toxic solvents, surfactants, and stabilizing additives that degrade electrical conductivity and require high-temperature post-processing. On the other hand, LIG is limited by the substrate. Here, this study introduces an additive manufacturing method for dry-printing carbon nanomaterials, ranging from amorphous carbon to crystalline graphene-like structures, on various substrates. The system utilizes laser ablation of a solid graphite target to create pure carbon nanoparticles in situ and on demand. An inert gas carries the nanoparticles onto the substrate, where they can be deposited either as amorphous structures or laser-sintered in real time to form various graphitic structures. The study of laser processing parameters, specifically fluence and pulse repetition frequency, revealed three unique regimes of nanostructure evolution that influence the morphological and electrical properties of these printed structures. Raman spectroscopy confirmed graphitization with a resistivity slightly higher than that of the bulk graphite target. The conductivity/resistivity could be tuned as a function of sintering laser power. Scanning transmission electron microscopy (STEM) revealed that turbostratic nanographene formed with an interlayer spacing of 0.40 nm. Despite ink-based printing methods, such as screen printing, inkjet printing (IJP), and aerosol jet printing (AJP), this eco-friendly and green manufacturing technique could eliminate toxic chemicals, reduce environmental impact, and enable single-step fabrication of carbon-based devices for applications in wearable sensors, energy storage, flexible electronics, and Internet of Things (IoT) devices.

Additive nanomanufacturing↗

DOE OSTI2024

A Gaussian Process-Based extended Goldak heat source model for finite element simulation of laser powder bed fusion additive manufacturing process

In this study, laser powder bed fusion (L-PBF) additive manufacturing (AM) is a key enabling technology to manufacture highly complex and integrated metallic structures. In L-PBF AM process, the melting of the metal powders and the layers underneath can be governed by either “conduction mode” or “keyhole mode”, with the keyhole mode reportedly leading to porosity and decreased strength and ductility by many studies. In part scale simulations, finite element (FE) model is often used to study the temperature distribution during printing and to predict the residual stress, where a volumetric heat flux with a Gaussian or a double ellipsoidal (Goldak) distribution is often applied as the laser heat source. However, the above heat source models can only capture the melt pool shape in the conduction mode, and fail to capture the transition to keyhole melting mode when the process parameters change. To overcome this inaccuracy, an extended Goldak heat source model is proposed by introducing a laser penetration term as a function of laser parameters obtained from a Gaussian-Process (GP) model. The model is validated by “2D pad” AlSi10Mg L-PBF experiments under a wide range of laser power, scan speed, and laser focus offset, and the results show the model successfully captures the measured melt pool shape in all conditions.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Coating adhesion of a chromate-containing epoxy primer on Al2024-T3 surface processed by laser-interference

In this work, the coating adhesion test results are presented for a primer that was coated on laser-interference structured surfaces of as-received Al2024-T3 specimens, i.e., without employing any polishing, cleaning, or any other surface alteration techniques. All of the laser-interference processing was performed by splitting the primary beam of a Q-switched Nd:YAG pulsed nanosecond laser into two beams and focused them to the same spot. The specimens were spray painted with a chromate-containing epoxy primer, CA7233, compliant to MIL-PRF-23377 Type I Class C2 specification. The adhesion of primer on Al surface with different treatments was assessed using the ASTM D3359 X-cut and cross-hatch tests. It was found that the laser processed specimens meet the performance requirements in the coating adhesion specifications by having a higher or identical ranking for coating adhesion specimens than those prepared with current state-of-the-art chemical conversion or sulfuric acid anodizing. The rastering with either 4 mm/s or 6 mm/s with a laser fluence of 1.78 J/cm2 is recommended to attain acceptable coating adhesion, even higher than that with the anodizing surface treatment.These results indicate that laser-interference shows significant potential as a non-chemical surface preparation technique for these coatings.

36 MATERIALS SCIENCE↗

DOE OSTI2026

X-ray observation of individual Ti-6Al-4V spherical powder particle impact in an in-situ operando laser directed energy deposition system

Understanding the particle capture mechanism in the laser directed energy deposition additive manufacturing process provides a foundation for improving productivity and reducing material loss. Capturing this phenomenon is challenging due to its highly transient time interval. To analyze the impact behavior of spherical Ti-6Al-4V powder, a custom laser directed energy deposition system was designed to control the deposition of individual particles. Synchrotron X-ray imaging at 24 kHz monitored the impact dynamics of individual powder particles. A multi-physics model based on the Smoothed-Particle Hydrodynamics scheme supported the analysis by providing the temperature and velocity fields of the molten pool. Results revealed that in laser directed energy deposition, surface tension forces dominated the powder–molten pool interaction. Hydrophobic Ti-6Al-4V powder particles had an equilibrium contact angle of 121 degrees with their molten state. Furthermore, Ti-6Al-4V powder particles required a high impact velocity (6 to 12 m/s) to transition from oscillation to submergence behavior. Lastly, oscillating powder particles that impacted near the location of the laser beam exhibited faster melting, highlighting the contribution of the laser beam to the melting mechanism. This work lays the foundation for investigations of powder particle impact in laser directed deposition and supports the validation of numerical models of powder–molten pool interactions.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Formation of uranium oxy-carbide and uranium carbide via conversion of polymer covered uranium dioxide by laser-based thermal processing

Conventional formation of carbonaceous uranium compounds requires bulk processing using furnace-based approaches. Here, a methodology employing polymer covered uranium dioxide and laser-based heating is explored to enable rapid, localized formation of carbonaceous uranium compounds. Specifically, heating of poly(methyl methacrylate) covered uranium dioxide powder to high temperatures using laser irradiation in argon and methane gaseous environments was investigated. Decomposition of material and reactions induced by laser irradiation were probed in situ by residual gas analysis using a benchtop mass spectrometer. In this study, to determine the effect on the resultant material phase, three different process parameters were varied: gaseous atmosphere, laser power, and laser irradiation time. Material processed under varying conditions was analyzed using powder X-ray diffraction and scanning electron microscopy. This work realized the conversion of uranium dioxide into uranium oxy-carbide(s) and uranium carbide(s) phases, at over 60 wt.%, via the polymer surface application and laser-based thermal decomposition methodology.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Laser strengthening of additive manufactured edge seal for vacuum insulated glazing with micro-size glass frit

Sealing of glass edge is a key step in developing cost-effective and durable vacuum insulated glazing for the drive towards net-zero energy buildings. In this study, to achieve a high-strength sealing with scalable and low-cost processing, we investigated a novel sealing method based on additive manufacturing and laser process and reported quantitative analysis of the laser assisted method sealing strength and the requirement of vacuum insulation glazing. Micro-size glass frits in printing ink and a continuous-wave laser curing were employed to allow the formation of a hermetic bonding layer with low thermal budget. Controlling various sealing parameters including laser traveling speed, spot diameter, and laser power, the water seepage and mechanical strength of the resulting glass-to-glass bonding were examined. Through the response surface methodology, we identified the optimized sealing condition where the bonding strength reached 5.68 MPa. A comparation of the bonding strength between thermal sealing method and laser-assisted method has been analyzed as well.

42 ENGINEERING↗

DOE OSTI2026

Innovative laser-based methods for monitoring fuel retention in ITER

This paper addresses the challenge of tritium inventory management in ITER and future fusion reactors, highlighting the importance of accurate tritium measurement and its spatial distribution within the vacuum vessel. Given ITER’s operational constraints, especially the limit on tritium retention, precise measurement is essential for both safety and regulatory compliance. To tackle these questions, the paper presents the T-monitor diagnostic system developed by Forschungszentrum Jülich, which uses Laser-Induced Desorption (LID) in combination with Diagnostic Residual Gas Analysis (DRGA) to measure hydrogen isotope concentrations on the surface of divertor tiles. The system integrates a high-power laser, advanced optical components, and a Fast Scanning Mirror Unit (FSMU) for accurate laser spot positioning with rapid response. Designed to measure in situ tritium retention, the diagnostic provides high-resolution spatial mapping, vital for evaluating detritiation strategies. The laser heating process increases the divertor surface temperature to 1600 K within the laser spot, promoting hydrogen isotope desorption. Accurate measurements require the precise control of laser parameters, including pulse duration and spot size, with a target relative accuracy of 20%. The optical design includes both in-vessel and ex-vessel components, such as durable high-reflectivity mirrors made of gold and copper, selected not only for their infrared performance but also for their transmission of visible wavelengths for observation purposes. To protect optical components from contamination, a pneumatic shutter is used.

Hydrogen isotopes↗

DOE OSTI2020

Laser-assisted embedding of all-glass optical fiber sensors into bulk ceramics for high-temperature applications

We develop a laser-assisted sensor embedding process to embed all-glass optical fiber sensors into bulk ceramics for high-temperature applications. A specially designed two-step microchannel was fabricated on an Al 2 O 3 substrate for sensor embedment using a picosecond (ps) laser. An optical fiber Intrinsic Fabry-Perot Interferometer (IFPI) sensor was embedded at the bottom of the microchannel and covered by Al 2 O 3 slurry which was subsequently sintered by a CO 2 laser. The sensor spectrum was in-situ monitored during the laser sintering process to ensure the survival of the sensor and optimize the laser sintering parameters. By testing in furnace through high temperature, the embedded optical fiber shows improved stability after CO 2 laser sealing, resulting in the linear temperature response of the embedded optical fiber IFPI sensor. To improve the embedded IFPI sensor for thermal strain measurement, a dummy fiber was co-embedded with the sensing fiber to improve the mechanical bonding between the sensing fiber and the ceramic substrate so that the thermal strain of the ceramic substrate can apply on the sensing fiber. The response sensitivity, measurement repeatability and high-temperature long-term stability of the embedded optical fiber IFPI sensor were evaluated in this work.

47 OTHER INSTRUMENTATION↗

DOE OSTI2022

Laser spectroscopy for the study of exotic nuclei

Investigation into the properties and structure of unstable nuclei far from stability is a key avenue of research in modern nuclear physics. These efforts are motivated by the continual observation of unexpected structure phenomena in nuclei with unusual proton-to-neutron ratios. In recent decades, laser spectroscopy techniques have made significant contributions in our understanding of exotic nuclei in different mass regions encompassing almost the entire nuclear chart. This is achieved through determining multiple fundamental properties of nuclear ground and isomeric states, such as nuclear spins, magnetic dipole and electric quadrupole moments and charge radii, via the measurement of hyperfine structures and isotope shifts in the atomic or ionic spectra of the nuclei of interest. These properties offer prominent tests of recently developed state-of-the-art nuclear theory and help to stimulate new developments in improving the many-body methods and nucleon–nucleon interactions at the core of these models. With the aim of exploring more exotic short-lived nuclei located ever closer to the proton and neutron driplines, laser spectroscopy techniques, with their continuous technological developments towards higher resolution and higher sensitivity, are extensively employed at current- and next-generation radioactive ion beam facilities worldwide. Ongoing efforts in parallel promise to improve the availability of these even more exotic species at next-generation facilities. Very recently, an innovative application of laser spectroscopy on molecules containing short-lived nuclei has been demonstrated offering additional opportunities for several fields of research, e.g. fundamental symmetry studies and astrophysics. Here, in this review, the basic nuclear properties measurable with laser spectroscopy will be introduced. How these observables are associated with nuclear structure and nucleon–nucleon interactions will be discussed. Following this, a general overview of different laser spectroscopy methods will be given with particular emphasis on technical advancements reported in recent years. The main focus of this article is to review the numerous highlights that have resulted from studying exotic nuclei in different mass regions with laser spectroscopy techniques since the last edition in this series. Finally, the challenges facing the field in addition to future opportunities will be discussed.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2025

Spectral emission characteristics near 646 nm and plasma properties of laser-induced plasma of gaseous uranium hexafluoride

We present a detailed investigation of the temporal evolution of line and continuum emissions in laser-induced breakdown spectroscopy (LIBS) of gaseous uranium hexafluoride (UF 6 ), focusing on the spectral region near 646 nm. Spectral emission features, signal-to-background ratios (SBRs) of selected uranium lines, and spectral linewidths were examined under varying UF 6 pressures (15–60 Torr) and laser pulse energies (10–60 mJ). Higher pressures and pulse energies enhanced continuum emission and reduced SBRs but did not cause significant spectral congestion. Additional studies with the use of different laser systems, including nanosecond-pulsed Nd:YAG lasers (at fundamental and various harmonics) and a femtosecond-pulsed Ti:sapphire laser, revealed long-lived plasma continua in all cases. This persistent continuum is attributed to a pseudo-continuum from overlapping molecular emissions, as its intensity scales linearly with electron number density, deviating from the expected quadratic dependence of classical ion–electron interactions for free-free and free-bound continuum emission. Based on plasma persistence time, SBR, U II/U I intensity ratios, and electronic excitation temperature, no fundamental advantage was found for femtosecond-pulsed lasers over conventional nanosecond-pulsed ones for UF 6 enrichment assay with direct LIBS measurement.

Laser-induced breakdown spectroscopy↗

DOE OSTI2024

Recycling of silver from silicon solar cells by laser debonding

A laser-debonding approach to silver electrode recovery from solar cells is presented to address the critical need for efficient and eco-friendly recycling methods. The study explores the use of UV nanosecond and IR continuous-wave lasers to precisely debond silver electrodes from silicon wafers. By optimizing parameters like laser power, scan speed, and the number of passes, intact silver electrical contact lines were recovered from solar cells. Scanning electron microscopy with energy-dispersive X-ray spectroscopy (SEM-EDS) analysis confirmed the successful separation of silver from silicon wafers. Furthermore, an increase in the number of laser passes led to the production of silver microparticles, as validated by morphology and compositional studies using EDS. The estimated silver is approximately 90 mg for the Si solar cells of 15.4 * 15.4 cm 2 used in the study. To achieve a large area recovery of silver, a MATLAB code incorporating detection algorithms and specific criteria to automate laser scanning by accurately identifying the location of silver electrodes was developed. This presented laser debonding method is not confined to silicon solar cells but can be extended to other solar cell types featuring metal electrodes, offering a versatile solution. By minimizing the use of hazardous chemicals and reducing operational costs, the developed process aligns with the imperative of environmentally responsible photovoltaic waste management.

14 SOLAR ENERGY↗

DOE OSTI2025

Excitation Laser Energy Dependence of the Gap-Mode TERS Spectra of WS 2 and MoS 2 on Silver

In this work we present a systematic study of the dependence of the gap mode tip-enhanced Raman scattering (TERS) response of the mono- and bi-layer WS 2 and MoS 2 on silver as a function of the excitation laser energy in a broad spectral range from 473nm to 830 nm. For this purpose, we collected consecutive TERS maps of the same area in the sample containing mono-and bi-layer regions with the same TERS probe with 6 different excitation lasers. To decrease the number of collected TERS maps, we used for the first time to the best of our knowledge, concurrent excitation and collection with two lasers simultaneously. We found that the E 2g /A 1g peak intensity ratio for the bilayer WS 2 @Ag and the ratio of the A’/A 1g peak intensity of the out-of-plane mode for the mono- and the bilayer, change in a significantly non-monotonous way as the excitation laser energy is swept from 1.58 eV to 2.62 eV. The former ratio increases at energies corresponding to A and B excitons (~2.0 eV and 2.4 eV correspondingly) in bilayer WS 2 . The absolute intensity of the A’ peak in the monolayer, and correspondingly the A’/A 1g ratio, is surprisingly high at lower excitation energies, but dips dramatically at the energy corresponding to the A exciton, being restored partially in between A and B excitons, but still showing the descending trend as the excitation laser energy increases. A somewhat similar picture was observed in mono- and bi-layers of MoS 2 @Ag, though the existing set of excitation lasers did not match the excitonic profile of this material as nicely as for the case of WS 2 . We attribute the observed behavior to the presence of intermediate (Fano resonance) or strong (Rabi splitting) coupling between the excitons in transition metal dichalcogenides (TMDs) and the plasmons in the tip-substrate nanocavity. This is akin to the so-called Fano (Rabi) transparency experimentally observed in far field scattering from transition metal dichalcogenides between two plasmonic metals. The possibility of the formation of intermediate/strong coupling between the excitonic resonances in TMDs and the nanocavity re-evaluates the role of various resonances in the gap-mode TERS and should become an important factor to be considered by TERS practitioners during planning the experiments. Lastly, based on observed phenomena and its explanation, we propose the “ideal” substrate for efficient TERS and tip enhanced photoluminescence (TEPL) measurements.

Raman spectroscopy↗

DOE OSTI2021

Microcoulomb (0.7 ± $$\frac{0.4}{0.2}$$ μC) laser plasma accelerator on OMEGA EP

Abstract Laser-plasma accelerators (LPAs) driven by picosecond-scale, kilojoule-class lasers can generate particle beams and x-ray sources that could be utilized in experiments driven by multi-kilojoule, high-energy-density science (HEDS) drivers such as the OMEGA laser at the Laboratory for Laser Energetics (LLE) or the National Ignition Facility at Lawrence Livermore National Laboratory. This paper reports on the development of the first LPA driven by a short-pulse, kilojoule-class laser (OMEGA EP) connected to a multi-kilojoule HEDS driver (OMEGA). In experiments, electron beams were produced with electron energies greater than 200 MeV, divergences as low as 32 mrad, charge greater than 700 nC, and conversion efficiencies from laser energy to electron energy up to 11%. The electron beam charge scales with both the normalized vector potential and plasma density. These electron beams show promise as a method to generate MeV-class radiography sources and improved-flux broadband x-ray sources at HEDS drivers.

43 PARTICLE ACCELERATORS↗

DOE OSTI2025

Three-dimensional characterization of modifications in sapphire exposed to laser-induced damage using multimodal spectral microimaging

Sapphire (Al 2 O 3 ) is a commonly used dielectric material with many applications in lasers and optical systems. Owing to its high resistivity to laser induced damage, it is particularly suitable for use in high power laser systems. This work focuses on developing techniques to characterize material modifications in sapphire. These techniques were applied following localized laser induced ablation, commonly referred to as laser-damage, resulting from exposure to single 100-ps and 6-ns pulses. Measurements of fluorescence-based piezospectroscopy and confocal Raman microscopy were performed with spatial resolution on the order of 1 μ m. Raman microscopy reveals that the relaxation of material exposed to the rapid laser heating, elastic and viscoplastic deformation, melting, and solidification leads to the formation of a polycrystalline material phase. In addition, narrowband fluorescence lines, referred to as R 1 and R 2 , exhibit pressure-sensitive changes to their spectral profiles, allowing 3D internal stresses to be recorded with spatial resolution of the order of a few micrometers.

Laser-damage↗

DOE OSTI2021

Experimental and calculational investigation of laser-heated additive manufactured foams

Foam materials are starting to find application in laser-heated Hohlraums used to drive inertial confinement fusion implosions. Foams made using additive manufacturing (AM) techniques are now available and may have advantages over traditional chemical (aerogel) foams. Here, we present new experimental data on laser-heated AM foams. Samples of four different types of printed AM foams were heated using a single 527 nm laser beam at the Jupiter Laser Facility. The laser pulse was ∼180 J square pulse with an FWHM of 1.6 ns and a peak intensity of 3–4 × 1014 W/cm2. The foam densities ranged from 12 to 93 mg/cc (all supercritical for 527 nm light). We measured the backscattered light (power and spectrum), the transmitted light, side-on x-ray images, and the Ti K-shell emission that was used to infer the time-integrated temperature. The fraction of backscattered light was 6%–15% of the input laser energy. The pure carbon foam sample had less backscatter than a C8H9O3 foam of similar density, which was consistent with multi-fluid calculations that predicted less ion heating for the C8H9O3 foam. The level of backscatter and the thermal front speeds for the AM foams were similar to values measured for stochastic (aerogel) foams under similar conditions.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Mitigation of mode-one asymmetry in laser-direct-drive inertial confinement fusion implosions

Nonuniformities present in the laser illumination and target in laser-driven inertial confinement fusion experiments lead to an asymmetric compression of the target, resulting in an inefficient conversion of shell kinetic energy to thermal energy of the hot-spot plasma. In this paper, the effects of asymmetric compression of cryogenic deuterium tritium laser-direct-drive implosions are examined using a suite of nuclear and x-ray diagnostics on the OMEGA laser. The neutron-averaged hot-spot velocity (u → hs ) and apparent ion temperature (T i ) asymmetry are determined from neutron time-of-flight measurements of the primary deuterium tritium fusion neutron energy spectrum, while the areal density (ρR) of the compressed fuel surrounding the hot spot is inferred from measurements of the scattered neutron energy spectrum. Here, the low-mode perturbations of the hot-spot shape are characterized from x-ray self-emission images recorded along three quasi-orthogonal lines of sight. Implosions with significant mode-1 laser drive asymmetries show large hot-spot velocities (>100 km/s) in a direction consistent with the hot-spot elongation observed in x-ray images, measured T i asymmetry, and ρR asymmetry. Laser drive corrections have been applied through shifting the initial target location in order to mitigate the observed asymmetry. With the asymmetry corrected, a more-symmetric hot spot is observed with reduced u → hs , T i asymmetry, ρR asymmetry, and a 30% increase in the fusion yield.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

Effect of laser preheat in magnetized liner inertial fusion at OMEGA

Integrated magnetized liner inertial fusion (MagLIF) experiments on the OMEGA laser system are modeled to investigate the effects of laser preheat on implosion performance. In both simulations and experiments, preheating the fuel with a laser enhances the neutron yield, with the maximum yield occurring at an optimal preheat laser energy. Increasing the preheat energy past the optimal value reduces the neutron yield. In simulations, the rate of the drop in neutron yield depends on the inclusion of the Nernst effect. The Nernst effect advects the magnetic field away from the center of the fuel region during the preheat stage of MagLIF on OMEGA and weakens magnetic-flux compression. If the Nernst effect is not included, the simulated drop in yield past the optimal preheat laser energy is more gradual as opposed to the sharper drop seen in experiments. Simulations are able to model trend in measured ion temperatures seen in experiments. Here, a mix model is used to show that including mix from the wall in the simulated fuel region further degrades the yield and lowers the optimal preheat laser energy. Simulations with mix predict that increasing the initial axial magnetic field may still enhance yield performance in integrated implosions.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2022

Simulating the filamentation of smoothed laser beams with three-dimensional nonlinear dynamics

In a plasma, the ponderomotive force of an inhomogeneous electromagnetic field expels plasma from regions of high intensity. When a laser propagates through a plasma, this force creates density wells that subsequently modify the index of refraction. The beam refracts and focuses into these wells and may filament. In extreme cases, the laser beam will spray due to increasing angular divergence of the beam. The threshold for ponderomotive self-focusing is well established for isolated laser hotspots or speckles. Here, we define a practical threshold for characterizing the filamentation of thousands of speckles that are found in the focal plane of high-power laser beams spatially smoothed with random phase plates as used at high energy and power laser facilities studying inertial confinement fusion. This threshold is tested against three-dimensional simulations of speckled laser light propagating through plasma. Four metrics are applied to assess filamentation: the fraction of power above five times the average intensity, an effective f-number, the mean-squared perpendicular wavenumber, and the fraction of rarefied density with deviation from the initial density exceeding | δn/ n| = 0.1. The speckled beams studied are generated by random phase plates, both with and without additional polarization smoothing, in a parameter regime of relevance to indirect drive experiments. While filamentation has been discussed extensively in the literature, we believe this to be the first published simulation study with three-dimensional nonlinear hydrodynamics that addresses the onset threshold of ponderomotive filamentation and establishes the lengths and time scales necessary to reach a statistical steady state.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗