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All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Effect of hatch spacing and laser power on microstructure, texture, and thermomechanical properties of laser powder bed fusion (L-PBF) additively manufactured NiTi

This study systematically evaluates the effects of laser powder bed fusion additive manufacturing (L-PBF-AM) parameters (hatch spacing and laser power) on the thermomechanical behavior and microstructure of Ni 50.8 Ti 49.2 shape memory alloy. The samples were fabricated with hatch spacings from 40 to 240 µm and laser powers of 50 and 100 W at a constant scanning speed of 125 mm/s, resulting in parts with volumetric energy density levels from 55 to 666 J/mm 3 and two sets of linear energy densities of 0.4 and 0.8 J/mm. The results showed a reduced melt pool size and discontinuity of scan tracks with decreased laser power. Additionally, the porosity level was increased with larger hatch spacing and lower laser power. More notably, the transformation temperatures increased, and the critical stress, recoverable strain, and functional stability of samples improved with lower hatch spacing, where the recovery ratio of up to 90% was observed, regardless of the employed laser power. This study also discussed the relationship between the fabrication process and texture formation in the L-PBF-AM process. In conclusion, the advantage of L-PBF-AM was revealed in tailoring the microstructure from highly textured samples in [1 1 1] or [0 0 1] direction when hatch spacing lower than laser beam focused was employed, to the appearance of equiaxed solidification front with island grains and random orientations.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Measurement of 2D density profiles using a second-harmonic, dispersion interferometer

A second-harmonic, dispersion interferometer is used to image large-area (≃5 cm 2 ) plasma-jet and gas-jet density profiles. Achromatic telescopes magnify the diameters of the primary-laser beam (1064 nm) and its second-harmonic (532 nm) before probing the sample and de-magnify the beam diameters after the sample, where the primary beam transfers its phase change to a second, second-harmonic beam, allowing the sample’s dispersive-phase change to be measured between two, orthogonally polarized second harmonic beams. The telescopes produce an azimuthally symmetric, dispersive-phase shift in the sample + background phase-change image and in the background phase-change image, which is removed by digital subtraction. The interferometer’s performance was verified using standard-optical components as dispersive elements (BK7 lenses and wedge plates), resolving a minimum, phase-change sensitivity of ΔΦ min ≳ 15 mrad and spatial resolution of Δx res ≃ 100 μm. The phase change produced by unknown-density objects (a pulsed-plasma-jet and a pulsed-gas-jet) was measured, and their data were used to recover the original, 2D density profiles using an inverse Abel transform: peak-number density, N gas ≃ 6 × 10 20 cm –3 and N e ≃ 5 × 10 16 cm –3 ; line-integrated density, ∫N gas dl ~ 2 × 10 19 cm –2 and ∫N e dl ~ 1 × 10 16 cm –2 . The techniques and methods developed here are scalable to even larger probe-beam diameters and frame-capture rates, leading to a diagnostic capability that is well-suited for applications involving the real-time measurement of density.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS2003

Geoscience Laser Altimeter System (GLAS) on the ICESat Mission: Initial Science Measurement Performance

The Geoscience Laser Altimeter System is the space lidar on the NASA ICESat mission. Its design combines an altimeter with 5 cm precision with a laser pointing angle determination system and a dual wavelength cloud and aerosol lidar. GLAS measures the range to the Earth s surface with 1064 nm laser pulses. Each laser pulse produces a precision pointing measurement from the stellar reference system (SRS) and an echo pulse waveform, which permits range determination and waveform spreading analysis. The single shot ranging accuracy is < 10 cm for ice surfaces with slopes < 2 degrees. GLAS also measures atmospheric backscatter profiles at both 1064 and 532 nm. The 1064 nm measurements use an analog Si APD detector and measure the height and profile the backscatter signal from thicker clouds. The measurements at 532 nm use photon counting detectors, and will measure the vertical height distributions of optically thin clouds and aerosol layers Before launch, the measurement performance of GLAS was evaluated using a lidar test instrument called the Bench Check Equipment (BCE). The BCE was developed in parallel with GLAS and served as an inverse altimeter, inverse lidar and a stellar source simulator. It was used to simulate the range of expected optical inputs to the GLAS receiver by illuminating its telescope with simulated background light as well as laser echoes with known powers, energy levels, widths and delay times. The BCE also allowed monitoring of the transmitted laser energy, the angle measurements of the SRS, the co-alignment of the transmitted laser beam to the receiver line of sight, and performance of the flight science algorithms. Performance was evaluated during the GLAS development, before and after environmental tests, and after delivery to the spacecraft. The ICESat observatory was launched into a 94 degree inclination, 590 km altitude circular polar orbit on January 12,2003. Beginning in early February, GLAS was powered on tested in stages. Its 1064 nm optical receiver was evaluated in a several tests using both solar background light and an internal test source. Laser 1 was activated on February 20,2003. GLAS operated with Laser 1 for 38 continuous days on orbit using its 1064 nm receiver channel, producing over 130 million individual laser measurements of the Earth s surface and atmosphere. These nadir-pointed measurements fell along the ICESat s ground track, and spanned more than 4 cycles of the initial 8-day ICESat repeat orbit. The initial GLAS measurement set shows strong echo pulses from ranging to the surface topography, oceans, ice sheets and cloud tops, as well as profiles of clouds and aerosols. The GLAS measurements have unprecedented vertical and angular resolution, and show nearly continuous height profiles of ice, land and ocean surfaces or cloud tops, as well profiles of backscatter from thin clouds and aerosol layers. Examples of these GLAS measurements and an initial assessment of its science measurement performance will be presented.

Abshire, James B.↗
NASA NTRS2015

Efficient Third-Order Distributed Feedback Laser with Enhanced Beam Pattern

A third-order distributed feedback laser has an active medium disposed on a substrate as a linear array of segments having a series of periodically spaced interstices therebetween and a first conductive layer disposed on a surface of the active medium on each of the segments and along a strip from each of the segments to a conductive electrical contact pad for application of current along a path including the active medium. Upon application of a current through the active medium, the active medium functions as an optical waveguide, and there is established an alternating electric field, at a THz frequency, both in the active medium and emerging from the interstices. Spacing of adjacent segments is approximately half of a wavelength of the THz frequency in free space or an odd integral multiple thereof, so that the linear array has a coherence length greater than the length of the linear array.

Hu, Qing↗
DOE OSTI2021

High-resolution x-ray radiography with Fresnel zone plates on the University of Rochester’s OMEGA Laser Systems

Experiments performed at the Laboratory for Laser Energetics with a continuous-wave (cw) x-ray source and on the OMEGA and OMEGA EP Laser Systems have utilized a Fresnel zone plate (FZP) to obtain x-ray images with a spatial resolution as small as ~1.5 μm. Such FZP images were obtained with a charge-coupled device or a framing camera at energies ranging from 4.5 keV to 6.7 keV using x-ray line emission from both the cw source and high-intensity, laser-beam–illuminated metal foils. In all cases, the resolution test results are determined from patterns and grids backlit by these sources. Here, the resolutions obtained are shown to be due to a combination of the spectral content of the x-ray sources and detector resolution limited by the magnification of the images (14× to 22×). High-speed framing cameras were used to obtain FZP images with frame times as short as ~30 ps. Double-shell implosions on OMEGA were backlit by laser-irradiated Fe foils, thus obtaining a framing-camera–limited, FZP-image resolution of ~3 μm–4 μm.

47 OTHER INSTRUMENTATION↗
NASA NTRS1982

Density measurement in air with saturable absorbing seed gas

Approaches which have the potential to make density measurements in a compressible flow, where one or more laser beams are used as probes, were investigated. Saturation in sulfur hexafluoride iodine and a crossed beam technique where one beam acts as a saturating beam and the other is at low intensity and acts as a probe beam are considered. It is shown that a balance between an increase in fluorescence intensity with increasing pressure from line broadening and the normal decrease in intensity with increasing pressure from quenching can be used to develop a linear relation between fluorescence intensity and number density and lead to a new density measurement scheme. The method is used to obtain a density image of the cross section of an iodine seeded underexpanded supersonic jet of nitrogen, by illuminating the cross section by a sheet of laser light.

Baganoff, D.↗
NASA NTRS1994

The SILEX experiment system operations

The European Space Agency is going to conduct an inter orbit link experiment which will connect a low Earth orbiting satellite and a Geostationary satellite via optical terminals. This experiment has been called SILEX (Semiconductor Inter satellite Link EXperiment). Two payloads will be built. One called PASTEL (PASsager de TELecommunication) will be embarked on the French Earth observation satellite SPOT4. The future European experimental data relay satellite ARTEMIS (Advanced Relay and TEchnology MISsion) will carry the OPALE terminal (Optical PAyload Experiment). The principal characteristic of the mission is a 50 Megabits flow of data transmitted via the optical satellite link. The relay satellite will route the data via its feeder link thus permitting a real time reception in the European region of images taken by the observation satellite. The PASTEL terminal has been designed to cover up to 9 communication sessions per day with an average of 5. The number of daily contact opportunities with the low earth orbiting satellite will be increased and the duration will be much longer than the traditional passes over a ground station. The terminals have an autonomy of 24 hours with respect to ground control. Each terminal will contain its own orbit model and that of its counter terminal for orbit prediction and for precise computation of pointing direction. Due to the very narrow field of view of the communication laser beam, the orbit propagation calculation needs to be done with a very high accuracy. The European Space Agency is responsible for the operation of both terminals. A PASTEL Mission Control System (PMCS) is being developed to control the PASTEL terminal on board SPOT4. The PMCS will interface with the SPOT4 Control Centre for the execution of the PASTEL operations. The PMCS will also interface with the ARTEMIS Mission Control System for the planning and the coordination of the operation. It is the first time that laser technology will be used to support inter-satellite links in Europe. Due to the complexity and experimental character of this new optical technology, the SILEX experiment control facilities will be designed to allow as much operational flexibility as possible.

Demelenne, B.↗
NASA NTRS2008

Crack Offset Measurement With the Projected Laser Target Device

The device and associated analysis methodology summarized in this report were developed for the purpose of estimating the size of discontinuities in the surface of the foam that covers the Space Shuttle External Tank. These surface offsets are thought to be due to subsurface cracks in the foam insulation. The mathematical analysis and procedure described here provide a method to quantity the dimensions of the crack offset in a direction perpendicular to the surface, making use of the projected laser target device (PLTD) tool and a laser line projector. The keys to the construction and use of the PLTD are the following geometrical design requirements: Laser dots are on a square grid: length on a side. Laser beams are perpendicular to projected surface. Beams are parallel out to the distance being projected. The PLTD can be used to (1) calibrate fixed cameras of unknown magnification and orientation (far-field solution); (2) provide equivalent calibration to multiple cameras, previously achieved only by the use of known target points, for example, in 3.D foreign-object debris tracking on a fixed launch platform; (3) compute scaling for conventional 2.D images, and depth of field for 3.D images (near-field solution); and (4) in conjunction with a laser line projector, achieve accurate measurements of surface discontinuity (cracks) in a direction perpendicular to the surface.

Source record↗
DOE OSTI2024

SYS-5620-Project - Achieving Robust Laser Performance utilizing Historical Shot Experiments - A Systems Engineering Proposal

The National Ignition Facility (NIF) at Lawrence Livermore National Laboratory precisely guides, amplifies, reflects, and focuses 192 powerful laser beams into a target about the size of a pencil eraser in a few billionths of a second, delivering more than 2 million joules of ultraviolet energy and 500 trillion watts of peak power. A crucial goal of the system is to trigger precise implosions of fuel capsules. This is achieved by delivering all 192 beams at user-specified times and locations on the target, minimizing any deviation from the requested performance. Power requirements can vary substantially on each experiment and the facility supports numerous amplifier pumping configurations and their attendant nonlinear effects. To achieve the tight performance required across such a broad array of configurations, constant comparison of measured and requested power delivery are tracked and long-term trends analyzed as a guide to understanding future performance. A very common question asked is given the current state of the laser today – how well would a similar experiment from the past perform today? Additionally, if one were to specify an alternate amplifier configuration using today’s model would and damage limits be exceeded and would there be an increase in performance. The physics model used to make these predictions and equipment protection checks is called the Virtual Beamline (VBL). VBL is used with an incoming desired pulse shape and energy to be delivered on target, and then does an iterative solve to predict the needed injected pulse in the front-end of the system to achieve this result. To effectively guide and predict future NIF experiment performance, laser scientists explore current amplifier configurations and compare them with historical data utilizing a tool called the Reverify Toolbox.

42 ENGINEERING↗
DOE OSTI2021

In situ synchrotron X-ray imaging and mechanical properties characterization of additively manufactured high-entropy alloy composites

Laser beam directed energy deposition has become an increasingly popular advanced manufacturing technique for materials discovery as a result of the in situ alloying capability. In this study, we leverage an additive manufacturing enabled high throughput materials discovery approach to explore the composition space of a graded W x (CoCrFeMnNi) 100–x sample spanning 0 ≤ x ≤ 21 at%. In addition to microstructural and mechanical characterization, synchrotron high speed x-ray computer aided tomography was conducted on a W 20 (CoCrFeMnNi) 80 composition to visualize melting dynamics, powder-laser interactions, and remelting effects of previously consolidated material. Results reveal the formation of the Fe 7 W 6 intermetallic phase at W concentrations> 6 at%, despite the high configurational entropy. Unincorporated W particles also occurred at W concentrations> 10 at% accompanied by a dissolution band of Fe 7 W 6 at the W/matrix interface and hardness values greater than 400 HV. In this work, the primary strengthening mechanism is attributed to the reinforcement of the Fe 7 W 6 and W phases as a metal matrix composite. The in situ high speed x-ray imaging during remelting showed that an additional laser pass did not promote further mixing of the Fe 7 W 6 or W phases suggesting that, despite the dissolution of the W into the Fe 7 W 6 phase being thermodynamically favored, it is kinetically limited by the thickness/diffusivity of the intermetallic phase, and the rapid solidification of the laser-based process.

36 MATERIALS SCIENCE↗
NASA NTRS1974

Multiple target tracking and target attitude determination with a scanning laser radar

A scanning laser radar that can acquire and track single or multiple targets has recently been developed. Scan patterns have been designed for acquisition and tracking of one or more targets using a narrow laser beam. A synchronously scanned transmitter-receiver is used to acquire and track targets anywhere in a 376 x 376 element raster covering a 30 x 30 deg field. All scan patterns are electronically programmed, and the system automatically acquires and tracks the target or targets without the aid of an operator. The maximum tracking rate is 1.0 deg/sec (10.0 deg/sec) when used with a 1 kHz (10 kHz) scan rate. The estimated free space range against passive cooperative targets (corner cube reflectors) is 30 nautical miles. The laser radar has an accuracy of 10 cm (range) and 0.05 deg (angle). The developmental system is relatively small (1.5 cu ft), lightweight (60 lbs) and low-power-consuming (60 W).

Flom, T.↗
NASA NTRS1996

Feasibility Study of Velocity and Temperature Measurements of an Arcjet Flow using Laser Resonance Doppler Velocimetric (LRDV) Technique

Thermal Protection System (TPS) materials are used in space vehicles to shield from high heating environment encountered during their atmospheric reentry. Arcjet wind tunnels are used to simulate the flowfield encountered by the spacecrafts, and are used for testing TPS materials. How well these tests simulate the actual heating environment encountered by space vehicles depends on the characteristics of the simulated flow. The flow characterization requires the determination of temperature, concentration, and velocity of the various atomic and molecular species present in the flow. However, determining these parameters requires a complex set of both analytical and experimental procedures. The ability to properly simulate the flight environment is directly related to the accuracy with which these techniques can be used to define the arcjet Laser Resonance Doppler Velocimetric (LRDV) technique can be used to accurately determine the velocity and temperature of a gaseous species. In this technique, the medium is probed with a laser beam that is in resonance with an absorbing transition of the species. The absorption lineshape is Doppler-shifted due to the flow velocity of the species, and the frequency shift is detected as the variation in intensity of the fluorescence emitted by the species. Thus a measurement of the Doppler shift and the width of a spectral line can give both the temperature and the velocity of the flowfield. This summer, our project was to make a feasibility study to set up an experimental arrangement for the laser resonance Doppler velocimetric technique using a ring dye laser. Experiments required troubleshooting, cleaning, testing, and alignment of two lasers and several diagnostics instruments. All instruments and lasers necessary for the project worked well, but the output power of the broadband fundamental dye laser was limited to about 20 mW. This was quite low as compared to that necessary to obtain second harmonic oscillation at 327.49 nm for the LRDV studies. Further optimization of the dye laser optical elements is necessary before it can be used for the experiment, which requires narrowband (about 20 Mhz) laser operation.

Rob, Mohammad A.↗
DOE OSTI2019

CO{sub 2} laser-induced micro-plume treatment of silicon: technique and application

A method for treating the surface of crystalline silicon (α-Si) covered with a fused silica (SiO{sub 2}) plate by a laser-induced plume arising from the absorption of CO{sub 2} laser radiation in glass is presented. The mechanism of micro-plume formation and the effect of this micro-plume on α-Si sample are considered. The α-Si processing regimes were determined that relate the depth of the formed relief to the radiation power density, the temperature of the micro-plume formed during SiO{sub 2} irradiation was measured and reached 3000 K. The diffraction phase gratings were designed, manufactured on silicon, and tested, they successfully split 10.6 μm laser beam at 0 and ± 1 diffraction orders. The method belongs to the group of direct writing methods and is easily adapted to different types of diffraction elements on the surface of Si and other materials transparent to 10 μm irradiation.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Solid-to-plasma transition of polystyrene induced by a nanosecond laser pulse within the context of inertial confinement fusion

Laser Direct Drive (LDD) Inertial Confinement Fusion (ICF) involves irradiating a spherical target of thermonuclear fuel coated with an ablator, usually made of polystyrene. Laser energy absorption near the target surface leads to matter ablation, hydrodynamic shocks, and ultimately capsule implosion. The conservation of spherical symmetry is crucial for implosion efficiency, yet spatial modulations in laser intensity can induce nonuniformities, causing the laser imprint phenomenon. Understanding laser imprint, especially considering the initial solid state, is essential for advancing LDD ICF. A first microscopic model of solid-to-plasma transition was built in 2019, accounting for laser absorption in the solid state with a band structure based ionization model. This model has been improved to include chemical fragmentation and a more accurate description of electron collision frequency in various matter states. The latest development involves assessing the model reliability by comparing theoretical predictions with experimental observations. Despite the success of this approach, questions remain, leading to further investigations and observations under different irradiation conditions. This work presents an experiment with a nanosecond pulse, taking into account hydrodynamic effects, and measures transmission dynamics over the entire laser beam area to observe two-dimensional effects. As a result, the objective is to adapt the theoretical model, couple it with a hydrodynamic code, and observe additional effects related to the initial solid state.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

In-situ Observations of Directed Energy Deposition Additive Manufacturing Using High-Speed X-ray Imaging

In laser-based directed energy deposition (DED) additive manufacturing, interactions among the laser beam, particle flow, and melt pool influence the properties of the solidified final part. Two separate DED systems, one with high powder flow rates to represent industrial-scale DED processing and the other with low powder flow rates for individual particle tracking, were synchronized with the high-speed imaging setup at the Advanced Photon Source in Argonne National Laboratory. In-situ x-ray imaging of the DED process using both systems highlighted the influence of powder flow rates. Increased powder flow rates resulted in less laser absorption into the melt pool, leading to a transition from a keyhole mode to a melt pool without a keyhole but with surface fluctuations due to powder flow. Increased velocities of particles during powder flow resulted in a decrease in particle melting times and a greater propensity for porosity formation. Altogether, better understanding of the interactions that occur during various scales of the DED process will enable flexibility, control, and new materials development in DED-based additive manufacturing.

36 MATERIALS SCIENCE↗
NASA NTRS2011

Development of Multi-Beam Long Trace Profiler

In order to fulfill the angular resolution requirements and make the performance goals for future NASA missions feasible, it is crucial to develop instruments capable of fast and precise figure metrology of x-ray optical elements for further correction of the surface errors. The Long Trace Profilometer (LTP) is an instrument widely used for measuring the surface figure of grazing incidence X-ray mirrors. In the case of replicated optics designed for x-ray astronomy applications, such as mirrors and the corresponding mandrels have a cylindrical shape and their tangential profile is parabolic or hyperbolic. Modern LTPs have sub-microradian accuracy, but the measuring speed is very low, because the profilometer measures surface figure point by point using a single laser beam. The measurement rate can be significantly improved by replacing the single optical beam with multiple beams. The goal of this study is to demonstrate the viability of multi-beam metrology as a way of significantly improving the quality and affordability of replicated x-ray optics. The multi-beam LTP would allow one- and two-dimensional scanning with sub-microradian resolution and a measurement rate of about ten times faster compared to the current LTP. The design details of the instrument's optical layout and the status of optical tests will be presented.

Kilaru, Kiranmayee↗
DOE OSTI2023

Additive manufacturing process parameter determination for a new Fe-C-Cu alloy

As a potential replacement for stainless steel alloys commonly used to print parts with laser powder bed fusion, a new Cu precipitation strengthened ferrous alloy, with composition Fe-0.2C-6Cu (wt%), was recently developed. This material is Co- and Ni-free, printable, has mechanical properties comparable to that of high strength stainless steels (approximately 1300 MPa UTS), and is cost-advantaged relative to existing low-alloy steels for additive manufacturing of parts with complex shapes. To gain traction for broader application, optimal laser powder bed fusion (LPBF) processing conditions to produce nearly defect-free parts without compromising mechanical strength are needed. Here, an optimal processing window based upon laser speeds that achieve minimal porosity was quantified via comparisons of measured melt pool penetration, scan speeds, printed material density and laser beam energy density on a commercial LPBF unit operating at 350 W, 80 μm hatch spacing, and 50 μm layer thickness based upon optimal parameters for 17-4PH. Furthermore, the window is 300 to 500 mm/s to achieve >99.8 % dense Fe-0.2C-6Cu (wt%) specimens. Other defects such as burning, spatter, and lack of fusion were also avoided in this window. The window was validated with in-situ synchrotron X-ray imaging that enabled visualization of the vapor cavity, melting, and solidification during a single laser track scan on a miniature powder bed sample. In addition, in-situ infrared imaging provided temperature fields, cooling rate and solidification range, and confirmed minimal printing defects and spatter within the processing window.

36 MATERIALS SCIENCE↗