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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 1,027 records · Page 57
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Damping and mode shape modification for additively manufactured walls with captured powder

Here, this paper describes the fabrication, modeling, and dynamic testing of laser powder bed fusion stainless steel walls with captured powder cores. The purpose of the study is to determine the increased structural damping, or energy dissipation, and mode shape modification caused by the inclusion of the unmelted powder core within the solid walls. It is shown experimentally that the damping increases with larger powder core width and that the damping addition is mode dependent. Damping increases over the solid wall values by factors of 2.9–225 are reported depending on the mode number and core width. It is also seen that the mode shapes are distorted relative to the solid wall results as the core width is increased and wall thickness is decreased. Comparisons with finite element models confirm this trend.

42 ENGINEERING↗
DOE OSTI2023

Process Capability Study on the Volume Manufacturing of a Complex Rotating Automotive Component in Laser Powder Bed Fusion Additive Manufacturing

Oak Ridge National Lab (ORNL) and Ford Motor Company used an AddUp FormUp 350 to print a turbo wheel geometry to show feasibility of laser powder bed fusion (L-PBF) additive manufacturing (AM) in producing cost-effective components for automotive industries. L-PBF AM has potential to disrupt traditional manufacturing techniques by introducing novel materials and geometries that cannot otherwise be produced. Fundamental challenges associated with L-PBF include limitations on printing overhang geometries and resulting surface finish. In this collaboration, ORNL and Ford partnered with AddUp to show the viability of using L-PBF for an AM design turbine wheel while reducing as-fabricated surface roughness. A cost model associated with mass production was produced to analyze benefits of pursing LPBF AM compared to investment casting.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Demonstration of Complete Recycling Processes of Reversible Epoxies Using Solar Energy Conversion

Reversible epoxies using the Diels–Alder chemistry enables recycling processes through depolymerizing the polymer at higher temperature and then repolymerizing upon cooling. Compared to conventional bulk heating, photothermal heating can save time and resource and, consequently, reduce costs to reach an elevated temperature for recycling processes of the reversible epoxies. In previous studies, self‐healing of cracks and reattachments of two broken pieces have been presented using a laser; however, recycling of a sample as a whole is not feasible by using such a point light source. Herein, complete recycling processes are demonstrated utilizing an area light source, i.e., sunlight. Reversible epoxies are incorporated with carbon black and refractory plasmonic titanium nitride nanoparticles (NPs). Under concentrated (10 times) sunlight, they can generate sufficient heat (≈140 °C) to completely liquefy, reprocess, and reshape the samples multiple times. Recycling processes are validated by evaluation of mechanical properties for each cycle. Using an integrated experimental and theoretical approach, photothermal performance is investigated in terms of the dispersion and loading of photothermal NPs in the matrix, as well as the sample thickness. In this study, an insight is provided into the design of polymer/photothermal nanomaterial composites which can be sustainably recycled using abundant solar energy.

14 SOLAR ENERGY↗
DOE OSTI2024

Experimental investigation of heat treatments on the mechanical performance of grade 300 maraging steel strut-based lattices

Lightweight and strong components are essential for reducing energy consumption and enhancing efficiency. Lattice structures are one such geometry utilized to achieve weight reduction. This study investigates the mechanical properties of various lattice structures fabricated from Maraging Steel (EOS MS1) using the Direct Metal Laser Sintering (DMLS) method. The samples include three distinct cellular geometries: body-centered cubic (BCC), face-centered cubic (FCC), and octet truss configurations, which are subjected to tensile and compressive tests. The primary goal of this research is to evaluate the impact of heat treatment on the mechanical properties of cellular architecture under tensile and compressive loading conditions. Destructive, nondestructive testing, and simulation results were also obtained from different heat treatment processes. It was found that the age-hardened specimens performed the best overall in terms of ultimate tensile/compressive strength and elongation. The top-performing topologies in compression and tension were found to be the octet structure, as they were able to withstand the most loading and straining when compared to the other specimens.

Engineering↗
DOE OSTI2022

Accurate temperature diagnostics for matter under extreme conditions

The experimental investigation of matter under extreme densities and temperatures, as in astrophysical objects and nuclear fusion applications, constitutes one of the most active frontiers at the interface of material science, plasma physics, and engineering. The central obstacle is given by the rigorous interpretation of the experimental results, as even the diagnosis of basic parameters like the temperature T is rendered difficult at these extreme conditions. Here, we present a simple, approximation-free method to extract the temperature of arbitrarily complex materials in thermal equilibrium from X-ray Thomson scattering experiments, without the need for any simulations or an explicit deconvolution. Our paradigm can be readily implemented at modern facilities and corresponding experiments will have a profound impact on our understanding of warm dense matter and beyond, and open up a variety of appealing possibilities in the context of thermonuclear fusion, laboratory astrophysics, and related disciplines.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Experimental Tests of Lateral Bedload Transport Induced by a Yawed Submerged Vane Array in Open-Channel Flows

This work proposes the use of an array of yawed porous vanes to control the lateral bedload transport by locally steering bedform migration and maximize the amount of sediments redirected toward a potential sediment extraction system or bypass channel. A laboratory experiment was conducted in a quasifield-scale channel with an array of permeable vanes installed on one side, in live-bed conditions under bedload dominant regime, i.e., negligible suspended load. A baseline experiment without vanes was also performed for comparison. The evolution of migrating bedforms of different scales was tracked in space and time using a high-resolution, state-of-the-art laser scanning device. The bedload transport rate in the streamwise direction was first calculated using bedforms’ geometry and migration velocity, and then spatially distributed over the entire monitored area using a new Eulerian-averaged grid-mapping method. This allowed us to introduce a new methodology to estimate the lateral bedload transport using control volume theory and applying mass conservation. Quantitative assessments of lateral bedload transport along the channel yield consistent results, suggesting that the vanes effectively move sediments laterally as intended. Under the investigated setup, the maximum lateral sediment transport rate ranges from 9% to 18% of the whole domain-averaged streamwise transport rate. The developed methodology also allowed to identify the location where sediment capture could be maximized for the given vane spatial distribution.

42 ENGINEERING↗
DOE OSTI2024

On Quantum Rainbows: Density Operator in the Frequency-Bin Representation for Entangled Twin-Photons Generated With Sub-Threshold Microcombs

Kerr optical frequency combs are generated by pumping a high-Q integrated microresonator with a resonant laser. Below threshold, the pump laser field mediates the phenomenon of spontaneous four-wave mixing, where two pump photons are symmetrically up- and down-converted as twin photons that can be entangled across up to tens of eigenmodes in the spectral domain. While these room-temperature integrated photonic circuits are expected to play a central role in quantum technology, their high dimensionality and dissipative nature are a challenge for their theoretical description, therefore hindering the understanding of their properties and potential of performance. In this article, we develop a framework that permits to obtain an explicit solution for the density operator of quantum microcombs below threshold. Furthermore, this self-consistent theoretical description allows for their complete characterization, as well as for the analytical determination of various performance metrics such as fidelity, purity, and entropy.

42 ENGINEERING↗
DOE OSTI2024

Elastic Modulus Measurement at High Temperatures for Miniature Ceramic Samples Using Laser Micro-Machining and Thermal Mechanical Analyzer

In this paper, we demonstrate a method of measuring the flexural elastic modulus of ceramics at an intermediate (~millimeter) scale at high temperatures. We used a picosecond laser to precisely cut microbeams from the location of interest in a bulk ceramic. They had a cross-section of approximately 100 μm × 300 μm and a length of ~1 cm. They were then tested in a thermal mechanical analyzer at room temperature, 500 °C, 800 °C, and 1100 °C using the four-point flexural testing method. We compared the elastic moduli of high-purity Al2O3 and AlN measured by our method with the reported values in the literature and found that the difference was less than 5% for both materials. This paper provides a new and accurate method of characterizing the high-temperature elastic modulus of miniature samples extracted from representative/selected areas of bulk materials.

Chemistry↗
DOE OSTI2024

A strong fracture-resistant high-entropy alloy with nano-bridged honeycomb microstructure intrinsically toughened by 3D-printing

Strengthening materials via conventional “top-down” processes generally involves restricting dislocation movement by precipitation or grain refinement, which invariably restricts the movement of dislocations away from, or towards, a crack tip, thereby severely compromising their fracture resistance. In the present study, a high-entropy alloy Al0.5CrCoFeNi is produced by the laser powder-bed fusion process, a “bottom-up” additive manufacturing process similar to how nature builds structures, with the microstructure resembling a nano-bridged honeycomb structure consisting of a face-centered cubic (fcc) matrix and an interwoven hexagonal net of an ordered body-centered cubic B2 phase. While the B2 phase, combined with high-dislocation density and solid-solution strengthening, provides strength to the material, the nano-bridges of dislocations connecting the fcc cells, i.e., the channels between the B2 phase on the cell boundaries, provide highways for dislocation movement away from the crack tip. Consequently, the nature-inspired microstructure imparts the material with an excellent combination of strength and toughness.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Characterization of mechanical deformation in aluminum by optical second harmonic generation

Second harmonic generation (SHG), a laser-based surface technique, was used to characterize near-surface defect evolution associated with mechanical deformation in 2024-T3 aluminum due to tensile loads. Electron backscatter diffraction (EBSD) measurements were also performed to determine the geometrically necessary dislocation density before and after tensile deformation. Comparison of the EBSD and SHG results found that dislocation density and SHG signal are inversely proportional; tensile deformation in the plastic regime led to an increase in dislocation density and a decrease in SHG response. A similar trend was seen in the SHG results on as-received (unpolished) Al samples; SHG response decreases with extent of plastic deformation. Furthermore, this study suggests that SHG has potential as a nondestructive evaluation technique.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Optimal gas cooling with minimal aero-opticaldistortion for next generation high-average-power lasers (Progress report, Year 2)

Next-generation lasers that combine high-peak-power ultrashort pulses with high repetition rates have the potential to efficiently deliver the high-average-power outputs required for inertial fusion energy generation, laser-based particle acceleration, and to generate compact secondary x- and 𝛾-ray radiation sources, among others. The combination of long gain length with high surface-to-volume ratio to remove residual heat makes gas-cooled multi-slab amplifier heads an inherently aperture- and average power scalable technology that enables this new class of solid-state lasers, and their thermal management becomes the most pressing technical challenge. As the index-of refraction depends on the gas density, heat removal from the slab surfaces unavoidably entails scattering of propagated light from regions of high temperature fluctuations. The requirement to maximize convective heat extraction from the gain medium under the constraint of minimum optical aberration of the beam renders amplifier slab cooling a technological challenge at the intersection of aero-optics, fluid-mechanics and heat transfer. The goal of this research is to leverage computational fluid dynamics and aero optics simulations of different levels of fidelity to devise a numerical modeling and optimization framework for gas-cooled multi-slab amplifiers. The project will be conducted in close collaboration with the Advanced Photon Technologies Group at Lawrence Livermore National Laboratory, where a gas-cooled test stand for laser materials and thermal management structures will be developed and installed. The final goal of the collaborative effort is to manufacture and benchmark a physical prototype of an numerically optimized amplifier head design. Measurement data on solid-state and thermo-optical distortions will be used for the validation of the numerical models. The key technical challenge in this multi-objective design problem is that of balancing optimal heat removal with minimal optical distortion. To facilitate computationally efficient design optimization and, at the same time, deepen our basic understanding of the interaction of light with turbulence, a complementary study that combines high and low-fidelity flow simulations and aero-optical models is proposed. Along the lines of these two objectives and solution strategies, the project is organized into two thrusts.

42 ENGINEERING↗
DOE OSTI2024

X-ray induced grain boundary formation and grain rotation in Bi 2 Se 3

Optimizing grain boundary characteristics in polycrystalline materials can improve their properties. Many processing methods have been developed for grain boundary manipulation, including the use of intense radiation in certain applications. Here, in this work, we used X-ray free electron laser pulses to irradiate single-crystalline bismuth selenide (Bi 2 Se 3 ) and observed grain boundary formation and subsequent grain rotation in response to the X-ray radiation. Our observations with simultaneous transmission X-ray microscopy and X-ray diffraction demonstrate how intense X-ray radiation can rapidly change size and texture of grains.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

The interplay between vapour, liquid, and solid phases in laser powder bed fusion

The capability of producing complex, high performance metal parts on demand has established laser powder bed fusion (LPBF) as a promising additive manufacturing technology, yet deeper understanding of the laser-material interaction is crucial to exploit the potential of the process. By simultaneous in-situ synchrotron x-ray and schlieren imaging, we probe directly the interconnected fluid dynamics of the vapour jet formed by the laser and the depression it produces in the melt pool. The combined imaging shows the formation of a stable plume over stable surface depressions, which becomes chaotic following transition to a full keyhole. We quantify process instability across several parameter sets by analysing keyhole and plume morphologies, and identify a previously unreported threshold of the energy input required for stable line scans. The effect of the powder layer and its impact on process stability is explored. These high-speed visualisations of the fluid mechanics governing LPBF enable us to identify unfavourable process dynamics associated with unwanted porosity, aiding the design of process windows at higher power and speed, and providing the potential for in-process monitoring of process stability.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Floquet engineering of polaritonic amplification in dispersive photonic time crystals

In this study, we investigate the dynamics of dispersive photonic time crystals (PTCs) and their potential applications for controlling light-matter interaction. Using the Lorentz-Drude as dispersive material model, we analyze the effects of periodic modulation of dispersion parameters through both theoretical and numerical analysis, revealing the emergence of hybrid bandgaps from the interaction of polaritonic branches with distinctive characteristics. Our study demonstrates that dispersive PTCs offer novel excitation channels and amplification possibilities, that require lower modulation frequencies compared to nondispersive systems thus alleviating experimental challenges for the realization of PTCs in the optical regime. These findings pave the way for advancements in polaritonic lasing and resonant Raman scattering.

Classical optics↗
DOE OSTI2020

Characterization of groove density variation of VLS gratings with ALS XROL LTP-II in different operation modes

The long trace profiler, LTP-II, available at the Advanced Light Source (ALS) X-ray Optics Laboratory (XROL), was recently upgraded by replacing a multimode diode laser light source with a single-mode, wavelength-stabilized, fibercoupled diode laser system. The upgrade enables us to reliably characterize the lateral variation of groove density of variable-line-spacing (VLS) x-ray diffraction gratings. Here, we discuss the LTP-II performance with an example of measurements with a VLS grating with the groove density at the grating center of 300 lines/mm. For the measurements, we use the LTP-II in two different operation arrangements, the single Gaussian beam and the pencil beam interferometer arrangements. For each operation arrangement, we apply two data processing algorithms: with calculating the centroid position and with determining the position of a characteristic features of the detected beam intensity distributions. Additionally, we discuss the observed strong correlation between the LTP-II modes of operation and the resulted (extracted) groove density variations. We also speculate on possible origin of the correlation.

42 ENGINEERING↗
DOE OSTI2025

Diode laser pumps for future inertial fusion energy systems: status and perspectives

Diode laser pumps are a critical enabling technology for inertial fusion energy (IFE), and will remain the largest contributor to facility cost, even assuming tenfold cost-reduction at high volumes. An overview of diode requirements for IFE and a technology path to achieve them are presented.

Engineering - Electronic and electrical engineerin↗
DOE OSTI2024

Bioleaching ion-unexchangeable rare earth in ion-adsorption type rare earth waste tailing

Ion-adsorption type rare earth ores (IREO) in China serve as the primary source of medium and heavy rare earth globally. With the rapidly growing demand for rare earth elements (REEs) and the dwindling supply of premium IREO, enhancing the recovery of REEs, especially the ion-unexchangeable REEs with ultra-low content and ambiguous speciation from IREO or its tailing, has become a critical trend and challenge. Here, this study identified the occurrences of ion-unexchangeable REEs, primarily detected in Fe-enriched minerals, xenotime, and monazite of IREO using TESCAN integrated mineral analyzer (TIMA) and laser ablation inductively coupled plasma mass spectrometer (LA-ICP-MS) analysis. To extract these elusive REEs, a bioleaching technique utilizing Aspergillus niger (A. niger) metabolites was proposed, achieving a leaching yield of 31.4 wt%. Complementary sequential chemical extraction methods (SCEM), X-ray photoelectron spectroscopy (XPS), and density functional theory (DFT) calculations further elucidate the underlying mechanism, involving the carboxylic acid produced by the metabolic process of microbes that dissolves goethite by disrupting Fe—O bonds and liberating REEs, which complexed with carboxylate (R—COO—), to promote further dissolution. This work offers insight into enhancing the recovery of ion-unexchangeable REEs from IREO or its tailing, paving the way for sustainable and efficient rare earth mining practices.

42 ENGINEERING↗
DOE OSTI2023

Mapping the pathways of photo-induced ion migration in organic-inorganic hybrid halide perovskites

Abstract Organic-inorganic hybrid perovskites exhibiting exceptional photovoltaic and optoelectronic properties are of fundamental and practical interest, owing to their tunability and low manufacturing cost. For practical applications, however, challenges such as material instability and the photocurrent hysteresis occurring in perovskite solar cells under light exposure need to be understood and addressed. While extensive investigations have suggested that ion migration is a plausible origin of these detrimental effects, detailed understanding of the ion migration pathways remains elusive. Here, we report the characterization of photo-induced ion migration in perovskites using in situ laser illumination inside a scanning electron microscope, coupled with secondary electron imaging, energy-dispersive X-ray spectroscopy and cathodoluminescence with varying primary electron energies. Using methylammonium lead iodide and formamidinium lead iodide as model systems, we observed photo-induced long-range migration of halide ions over hundreds of micrometers and elucidated the transport pathways of various ions both near the surface and inside the bulk of the samples, including a surprising finding of the vertical migration of lead ions. Our study provides insights into ion migration processes in perovskites that can aid perovskite material design and processing in future applications.

14 SOLAR ENERGY↗